Ceramika Paradyż: High capacity and picking speeds in its automated rack-supported warehouse
Mecalux has designed Ceramika Paradyż an automated rack-supported warehouse with a capacity for more than 20,200 pallets in Poland
Ceramika Paradyż is a renowned Polish ceramics manufacturer that exports its products to over 50 countries around the world.
The company, known for its innovative production and storage processes incorporating the latest technology, contacted Mecalux to build it a rack-supported warehouse. Its two main objectives were to accommodate all its products and streamline the process of picking such heavy materials as ceramics.
Once the technical teams analyzed Ceramika Paradyż’s needs and designed the solution, construction began on the clad-rack warehouse. The building stands 82 feet tall by 318 feet long by 115 feet wide.
Just next to the facility, a two-story annex was set up to house different operations.
The 35,413-square-foot warehouse is made up of single-deep racking. It has a total of 45 racking units with 14 levels. Each aisle features a single-mast stacker crane for handling pallets.
In this facility, product turnover is classified according to the A-B-C analysis, which optimizes the movements of the handling equipment.
The various operations of this logistics center are distributed among the two levels of the annex to the clad-rack warehouse.
On the lower floor, goods are received from the production center, and finished orders are sent to the shipping area.
Many pallets arriving at the warehouse lack the appropriate quality to be stored. They are thus placed on slave pallets supplied by pallet stackers.
This entire goods flow process is executed by the facility’s automated handling equipment: stacker cranes, conveyors, preload channels, and transfer cars.
The upper floor is allocated to order picking. Six pick stations, with the option to add four more if necessary, have been specially designed and optimized to work ergonomically with such heavy material as ceramics.
Mecalux has also installed tables that can be raised to suitable heights for operators, and vacuum box lifters, which are ideal for heavy loads.
Pallets used for picking are moved from the warehouse to the pick stations first by means of electrified monorails and then by conveyors.
To prevent goods from entering and exiting out of sequence, the upper floor has a buffer that can temporarily slot up to 120 pallets at a time to ensure that they are distributed correctly.
Once the picking tasks have been completed, two transfer cars are charged with managing empty pallets, which are then reused.
The warehouse requires seamless coordination and strict control over all operations.
For this reason, Mecalux installed its Easy WMS warehouse management software.
This WMS communicates continuously with Ceramika Paradyż’s ERP system. It also incorporates the Galileo control module to ensure the proper operation of all automated technology in the facility.
Mecalux has built Ceramika Paradyż a new logistics center that maximizes throughput, increases load capacity, and manages its products efficiently.