End-to-end warehouse automation: from receiving to shipping

Following a detailed analysis of warehouse operations and close collaboration with the OMEGA team, KAPELOU’s conceptual department designed a tailor-made automation solution aligned with the company’s real-world business challenges. Together with the customer, we identified high-impact areas for optimization and selected the most effective equipment and technologies to boost warehouse performance.

Zone conveyor system – seamless movement across all warehouse areas

At the heart of the solution is a zone conveyor system designed to handle both corrugated cartons and plastic totes. The equipment ensures a fast, uninterrupted flow of goods from picking to sortation and inspection zones. Arranged in a ring around the perimeter of the warehouse’s first floor, the automated system creates a continuous loop that streamlines internal logistics and minimizes handling time, ensuring:

• continuous flow, faster throughput – cartons move automatically between warehouse zones, accelerating order processing;
• speedy shipping – packed orders are seamlessly transferred to the ground level, to the shipping area, cutting down preparation time before dispatch;
• automatic tote return – empty totes are automatically routed back to the picking area, maintaining a continuous and efficient picking cycle;
• less manual labor – automation reduces physical workload and boosts productivity in all areas.

Efficient vertical logistics: optimized performance at every level

To maximize available space, a 2,000 m² single-level platform and a three-tier mezzanine were built in the storage zone for small items. This multi-level storage system expanded the storage capacity and enabled high-efficiency equipment deployment across picking, sorting, packing, consolidation, and storage areas. At the same time, the mezzanine storage area preserved open access for staff and equipment on the ground floor, ensuring smooth, uninterrupted warehouse operations.

Storage replenishment with precision weight control

A dedicated receiving line has been implemented where goods are unloaded from pallets into cartons and automatically transported to the designated replenishment zones. To ensure storage accuracy, each box passes through an integrated weighing module. If the actual weight matches the expected value, the carton continues to the storage area. If there’s a discrepancy, it’s rerouted to the warehouse inspection area for verification.

Pick-by-Light and AGV: smart warehouse sortation area

To streamline warehouse order consolidation, we used Pick-by-Light technology in combination with AGVs. This integration speeds up order picking and improves accuracy. Before shipping, cartons are automatically strapped for secure transport. In the dispatch area, the 18-position divert sorter directs up to 1,000 load units per hour to their respective shipping destinations.

Automated warehouse workstations with tailored KAPELOU Software

For this project, KAPELOU developed a custom software solution designed to elevate speed, precision, and operator comfort at every stage in the warehouse sortation area. The WXS platform integrates multiple services and devices – including the warehouse’s WMS, AGV fleet, and Pick-by-Light – into one cohesive interface. At the automated workstation, warehouse operators are fully equipped: detailed product information, packing rules, and order data are presented in a single, intuitive window. The system alerts the operator when a picking wave is complete and trays are ready for dispatch to the shipping zone.
The result? Accuracy, visibility, and quality control of warehouse logistics in real time. The software enables the sorter to verify every action, minimizing errors and boosting warehouse sorting area operational performance.

Warehouse equipment and technologies implemented:

• platform with integrated mezzanine;
• driven roller conveyors;
• rotating powered roller sections;
• non-driven (gravity) roller conveyors;
• diverter sorter;
• weighing module;
• inclined belt conveyor;
• vertical conveyor;
• spiral conveyor;
• AGV;
• Pick-by-Light technology;
• barcode readers and label applicators;
• strapping machine.

Results. The automation project delivered measurable results across the board, doubling warehouse areas performance while streamlining warehouse logistics and maintaining workforce levels:

• significantly faster order picking and shorter delivery times;
• optimized use of warehouse space with increased storage area density;
• more than double the throughput per operator – packers and sorters now handle up to 150 lines per hour;
• reduced physical workload through automation of previously manual tasks.

This case is a powerful example of how a well-balanced automation strategy can dramatically boost warehouse areas efficiency – while also creating a safer, more comfortable workplace for employees. We’re grateful to OMEGA for their trust, forward-thinking mindset, and strong partnership. Together, we’ve built a modern, future-ready warehouse – scalable, efficient, and fully aligned with the company’s growth ambitions.