Fully automated warehouse for vegetable processing

The customer is a family-owned company specialising in the processing of fresh vegetables and is among Europe's leading specialist carrot processors.

To improve efficiency and safety, the customer decided to replace manual forklift transport between the sorting and filling lines and the carrot processing area with an automated logistics system. The existing transport method limited production capacity, traceability and process continuity.

The new warehouse had to be integrated into the existing production environment while preserving the available infrastructure. In addition, full traceability of every crate and optimal monitoring of product freshness were essential requirements.

Motus Handling delivered a fully automated storage and container handling system.

Empty containers are transported from the container washing installation to fourteen filling stations. After filling, containers are either sent directly to production or stored in the automated buffer warehouse. The 12-metre-high warehouse provides storage capacity for 1,516 containers and processes up to 240 containers per hour.

Four stacker cranes automatically store and retrieve containers for production. Before further processing, containers are automatically tipped, allowing the carrots to be washed, peeled, cut or packed. Empty containers are automatically returned to the washing installation, the warehouse or the filling department.

Through RFID identification and an integrated Warehouse Management System (WMS), every container remains fully traceable throughout the process. The system records the location, product type and storage duration of each container, ensuring maximum product freshness and FIFO control.

The installation includes:

• Automated crane warehouse
• RFID identification of every container
• WMS control and integration with customer systems
• Turn transfers
• Two transfer cars
• Accumulation chain conveyors
• Vertical transport systems
• Automated container washing installation
• Tipping stations for product feeding
• Hot-dip galvanised warehouse racks
• Powder-coated components for humid environments
• Complete turnkey project delivery

Today, the customer benefits from a nearly 24/7 operational buffer and transport system that provides complete control over container logistics while increasing production capacity, product quality and operational efficiency.

Key benefits:

• Significant reduction in internal forklift traffic
• Storage capacity of 1,516 containers
• Throughput of up to 240 containers per hour
• Full traceability through RFID and WMS integration
• Optimal product freshness through controlled storage and FIFO management
• Rapid availability of every product type for further processing
• Continuous production flow without manual intervention
• Short payback period achieved through higher efficiency