en.Wedoany.com Reported - Clavo Food Factory has deployed Mecalux's automated logistics solution at its Tordesillas facility, increasing storage capacity by 50% and reducing operation time by approximately 20% without expanding the warehouse area.

This company, specializing in ready-to-eat refrigerated and frozen foods, has an annual production capacity of 14,000 tons and supplies over 1,000 individual products to more than 42,000 restaurants worldwide. Facing growing demand, the factory needed to manage a large volume of raw materials and finished products below zero degrees within its existing area while maintaining temperature control, traceability, and efficiency.

The core of the solution is Mecalux's high-density 3D Automated Pallet Shuttle system, integrated with Easy WMS warehouse management software and mobile racking. Operating in a -24°C environment, autonomous shuttles handle the cross-aisle and cross-level movement of pallets, optimizing storage density while ensuring operational continuity.

The new system currently manages 5,827 pallets of raw materials and finished products. Alejandro Lara, Plant Manager at Clavo Food Factory, stated: "The 3D Automated Pallet Shuttle system has doubled storage capacity, reduced idle time, and lowered costs."

Previously, pallet positions in the freezer warehouse were assigned manually, lacking real-time inventory visibility. With the introduction of Easy WMS, the system automatically assigns storage locations and enables full traceability of food products along with real-time inventory visibility.

Iñaki Frías, Logistics Manager, explained: "We used to assign pallet positions manually; now the WMS does it automatically, eliminating the need to search for empty spaces." The system integrates with the company's ERP, allowing pre-allocation of incoming goods, improving warehouse order, and reducing processing time. "Easy WMS provides complete visibility of each pallet, helping us forecast demand and improving accuracy."

The order fulfillment process has also been optimized. The system coordinates picking and full-pallet shipments, for example, processing items that require picking first and then completing orders with remaining pallets, thereby reducing unnecessary movements and improving operational efficiency. The high-density design allows for denser storage within the same footprint, which is particularly critical in temperature-controlled environments, while optimized pallet movement also contributes to energy savings.

Alejandro Lara, Plant Manager at Clavo Food Factory, noted that customers have already experienced faster service, and the company can now handle higher operational volumes. The implementation of this project has enhanced supply chain efficiency and flexibility, helping to cope with demand peaks and supporting continued international expansion.

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