DECASA: High throughput picking and storage

A cutting-edge logistics complex, which combines management, efficiency and speed in its processes. It is noted for a high picking throughput, an essential solution for a company that manages more than 7,000 products.

Video transcription

DECASA, a company dedicated to the distribution of consumer products, is located in the Mexican state of Veracruz. Their logistics center has been designed and set up by Mecalux.

The result is a cutting-edge logistics complex, which combines management, efficiency and speed in its processes. It is noted for a high picking throughput, an essential solution for a company that manages more than 7,000 products.

We wanted a cost-effective system that would help us manage the processes within our supply chain and allow us to expand into the south-east of the country, with the opening of our new branch in Veracruz.

We compared several storage solution suppliers and chose Mecalux. They offered a comprehensive system that would manage the large number of SKUs we carry and would also deal with the enormous amount of stock in our warehouse.

This warehouse combines different systems. The first zone is the location of the AS/RS automated storage & retrieval system and the high-density Pallet Shuttle system. Adjacent is the picking area with multi-level bays and the sorter.

Goods enter the loading docks and are left in a stacking area awaiting placement.

The DECASA AS/RS is a 112 foot high by 223 foot long rack supported structure, with a capacity of 28,000 pallets.

Two AS/RS stacker cranes for pallets operate in the eight aisles that comprise the warehouse.

Running only a few stacker cranes results in significant cost savings, and all due to the transfer bridge.

The transfer bridge is in charge of moving the stacker cranes from one aisle to another.

The AS/RS stacker crane is placed and anchored to the bridge, which then moves sideways to the assigned aisle where the transfer takes place.

This solution is used in warehouses where the turnover of goods is not very high, but the storage volume is.

This transfer bridge helps us move the stacker cranes to each of the aisles. This maximizes the storage volume, optimizing costs related to the running of a rack supported installation, making it a more cost-effective solution in the end.


Both the input and output of goods take place at the front of the automated warehouse.

Assisted by a double transfer car, pallets are located in the corresponding aisle.

Right in the front of the AS/RS for pallets, two level high racks include the Mecalux Pallet Shuttle system.

DECASA locates its consumer products in this area.

The second large area of this logistics center is the picking area, with high-rise picking bays and the sorter.

Forklift operators are tasked with supplying the multi-level bays with goods flowing from both the warehouse and the Pallet Shuttle zone.

This provisioning takes place during the day so that from 9 pm onward operators can start picking.

The multi-level picking bays consist of three blocks of racks with five load levels. Levels 1 through 3 are set aside for picking. This is where live, pallet flow racks have been installed that meet FIFO flow demands, the first pallet in is the first out. Levels 4 and 5 include push-back racks used for product reserves that supply the first three levels quickly.

Operators pick the boxes specified to them by the system and place them on conveyor belts that run throughout the central area of the shelves, up to the far end of the warehouse.

There, a spiral conveyor raises boxes to the third level, where the boxes picked from the other three levels accumulate.

The boxes circulating on the conveyors of each multi-level installation merge onto a single conveyor called the sorter.

A scanner, located at the beginning of this sorter, identifies the boxes to find out to which order they are assigned. This system has sliding shoe sorters, installed in the slats of the conveyor. These push goods off into the chute corresponding to them.

There are 11 sloping chutes, which supply 11 loading docks, where dispatches are carried out.

This system makes it possible to prep orders by waves. Operators dispense boxes onto the conveyors, and the sorter prepares orders automatically.

Mecalux has been able to furnish a comprehensive, high throughput solution for DECASA, essential for fast and efficient picking, and to keep providing its customers with great customer service.