at the Spanish clothing manufacturer Velilla installed a new AS/RS system with 22,400 pallet spaces and a multishuttle-based sequencer existing miniload and multishuttle systems, the facility can now store approximately 600,000 cartons.
Dematic has successfully completed the third phase of a comprehensive automation project for the Spanish workwear manufacturer. The new state-of-the-art pallet warehouse enables the efficient processing of 18,000 stock keeping units (SKUs) and up to 500,000 orders per year. The expansion, the company says, lays an important foundation for Velilla's future growth.
The advantage provides
“For over 15 years, Velilla has worked closely with Dematic to ensure that automation in our facilities gives us the decisive edge, not only to meet our future growth forecasts, but also to stay ahead of the competition today,” says Antonio Tártalo, Operations and Logistics Manager at Velilla. The Spanish manufacturer of technical workwear has been in business for over 75 years and sells its products in more than 70 countries.
Integrated pallet storage. Photos (2): Dematic
A few years ago, the Velilla Group's flagship family-run brand, which anticipates average linear sales growth of around eleven percent per year until 2030, to expand its product range and sales volume. This required significantly larger new inventories and the installation of an automated pallet storage and retrieval system (AS/RS), enabling Velilla to flexibly increase capacity.
Pallets on demand
Thanks to their strategic expansion plans and the resulting gradual growth, the overall plans for the warehouse included an additional phase to meet increasing business demands.
The multishuttle-based sequencer sorts the large quantities of cartons delivered by Velilla and assembles reference pallets, which are then stored directly in the AS/RS. Finished cartons from the pallet area are either sent directly to shipping or temporarily stored in the Dematic miniload and multishuttle warehouse.
500,000 orders per year. Photo: Velilla
for both pallets with full cartons and those with empty cartons. All carton movements to the picking stations are centrally controlled from the checkout area, consolidating the processes of Miniload and Multishuttle. A corresponding return flow is also generated for the picked cartons .
The Dematic solution efficiently manages Velilla's extensive range of approximately 18,000 SKUs and processes different carton sizes precisely and flexibly. According to the manufacturer, it enables the processing of over 97,000 garments per day and 500,000 orders per year, thus supporting the workwear manufacturer's continuous growth. The integration is controlled by the warehouse management system, which ensures the seamless coordination of all automation levels.
Orderly handover
In the next step, the small Dematic multishuttle sorts the incoming packages and, according to the palletizing guidelines, hands the cartons over to the palletizing robot in the correct order. for some time now with Velilla indispensable for customers in the warehousing and logistics solutions market on the Iberian Peninsula .”
