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Automatic warehouse for frozen foods: Automha’s solution for the Pecaro company.

Two -27°C refrigerated rooms with a total of 12,000 fully automated pallets using the innovative AUTOSATMOVER System, which delivers high performances, maximum efficiency, and reliability.

Problem

Pacaro was a business founded on knowledge of the food industry and logistics distribution in the frozen field. The logistics of refrigeration is now the core business of Pacaro. which offers varied asset management of the service among which customers can find the solution that best suits their needs. The modern logistics platform of Pacaro in east Rome covers an area of 200,000 sqm with refrigerated storage of 110,000 m3. The development plan has made the new plant one of the major hubs in central Italy with its more than 22,000 pallets of frozen and fresh stock capacity. All operations related to the storage, preparation, shipment of refrigerated, frozen and deep-frozen food are carried out at the factory.

For this reason, the company has asked for Automha’s help through the creation of an automatic warehouse for frozen foods, to make their spaces, storage and picking times more efficient and reduce the energy impact.

Solution
In the span of three years, Automha has expanded the storage capacity from 10,000 LU to 22,000 LU through the automation of two new -27°C rooms, developed in two different phases but on the same, pre-existing area of reception/shipping of goods.

For the first refrigerated room, with a capacity of 4000 LU, Automha has structured a warehouse with channels arranged to use Autosat. This automatic satellite semi-automates storage operations but is even more unique because it performs the same in a temperature as low as -27°C thanks to lithium batteries.

Upon completion of the semi-automation of the first room, in 2011, we also made the second room from scratch for 8000 pallet spots. This room was already designed to be totally automated using 5 AUTOSATMOVERS, one for each level of service. Each of them was equipped with an AUTOSATSUPERCAP to work at a temperature of -27°C, a lift/descender for the servicing of all 5 levels of shelving/AUTOSATMOVERS, 1 service shuttle to the receiving/shipping area, accumulation conveyors for the incoming and outgoing load units. After this room was created and the system completely automated, we completed the automation of the first room. Automha has therefore replaced the two movable AUTOSAT equipped with forklifts with 5 AUTOSATMOVERS, each equipped with AUTOSATSUPERCAP.

Advantages

The system was made in 3 steps, so as not to burden productivity and client requests. Pacaro achieved considerable efficiency in economic, energy and logistics from the new warehouse.