The automation of the warehouse of the largest online retailer in Ukraine
Each of our projects is a new challenge and a new opportunity to create something extraordinary that has never been done before. Recently, we completed a large-scale project to automate the warehouse of the largest online retailer in Ukraine – ROZETKA – which we have been working on since 2016. During these 5 years, we have gradually improved the operation of the warehouse and gradually implemented all the set goals.
ROZETKA is a Ukrainian company that has been trusted by millions of Ukrainians for 17 years. In addition to being the most popular website in Ukraine, the company also has offline branches and distribution points across the country. In 2008, the first branch with an area of 120 m2 was opened, and in 2017, the first consumer market with an area of 6000 m2. By the beginning of 2022, there were already more than 250 shops and pick-up points. The assortment on the website includes more than 11 million products, including products from thousands of sellers on the online marketplace. To facilitate ordering, the company offers its own courier delivery, free delivery to shops and shipping through all postal operators.
To store so much goods and process customer orders quickly, extensive automation and a large storage area are necessary. ROZETKA commissioned KAPELOU to improve its warehouse processes.
With a storage area of 46,000 m2 and 24/7 operation, these were our objectives:
- storage of more than 275,000 products;
- acceleration of order processing;
- automatic descent and ascent of goods between levels;
- integration of the facilities into the WMS system.
In order to use every square metre of warehouse space effectively, KAPELOU developed a concept and detailed planning for warehouse automation together with the customer ROZETKA.
We installed platforms and mezzanines over an area of 30,000 m2. Our engineers made sure, that the constructions are extremely stable and designed for all kinds of loads. In addition, the products are easily accessible from all sides. The multi-storey metal constructions contain the storage and order-picking area in the form of shelving. The shelves have a modular design that allows the system to be completed or quickly changed as needed. This ensures maximum storage capacity for almost all possible goods.
In order to be able to transport the goods quickly and efficiently through the warehouse, KAPELOU designed, installed and commissioned a conveyor system over 5 km long. As we have our own production facilities, we were able to significantly shorten the time needed to manufacture and deliver the conveyor technology to the ROZETKA warehouse. The use of high-quality materials and the many years of experience of our specialists ensured smooth continuous operation of the entire system.
The complete automation system consists of:
- roller and belt conveyors;
- swivelling roller segments, infeed and outfeed diverters for changing the transport direction of boxes;
- container and pallet vertical conveyors;
- spiral conveyors that combine flows from different storage levels and serve as buffers.
The KAPELOU conveyor system is extremely energy efficient. This is achieved by synchronising logical zones, as only the sections where the boxes are located are in operation. To protect the goods from damage, the ZPA (Zero Pressure Zone) logic is integrated into the drive roller conveyor, which ensures the distance between the boxes.
To determine the weight of conveyed goods, weighing modules are installed in the conveyor. The weight measurement system is able to work even at high throughput, determine the data of the goods in 3 seconds and transmit the information to the WMS system. With the help of this module, it is easily possible to classify the goods according to the specified characteristics and carry out correct picking.
Full automation of the warehouse is one of the essential prerequisites for ROZETKA to be able to offer its customers fast order processing and a wide range of products, and to enable dealers in the market to benefit from all the advantages of automated warehouse systems. Reliable solutions, state-of-the-art technology, quality equipment from our own KAPELOU® production and reliable partners ensure high precision and speed in order processing in the ROZETKA warehouse.
Together with ROZETKA, we plan new projects and create an innovative future for Ukraine.