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Close Pallet handling automation: efficiency on every level
One of Ukraine’s largest bakery product suppliers approached KAPELOU – a trusted manufacturer and integrator of warehouse automation systems – with a clear goal: increase the warehouse capacity. The customer needed an automation strategy tailored to the specifics of baked goods and in full compliance with strict sanitary and hygiene requirements.
After a detailed analysis of the existing process flow, we worked closely with the customer to define key project objectives based on real warehouse challenges:
- increase storage capacity;
- ensure safe pallet transport between levels;
- boost pallet handling performance;
- reduce manual labor.
KAPELOU’s concept design team developed a tailor-made, integrated solution focused entirely on the customer’s operational needs. Every element was considered – from automated pallet transport and optimized use of pallet storage warehouse space to the ability to scale operations in the future.
Automated pallet flow – reduced strain, higher accuracy
To automate the movement of goods between zones and levels, we installed a vertical pallet conveyor and powered pallet conveyor. This ensures handling of 1200×800 mm hygienic plastic Euro pallets weighing up to 1,000 kg, which are loaded from both levels using a hydraulic pallet truck. The load is then automatically lifted or lowered.
The system supports bidirectional (reversible) movement. Transport mode is selected via a user-friendly touch interface on the control panel, ensuring intuitive operation for warehouse staff.
The vertical and powered conveyors deliver consistent, fast vertical and horizontal movement of pallets – significantly improving processing speed and accuracy, reducing manual handling, and lowering physical strain on employees.
Platform integration – more usable space, zero construction
We installed a custom-built storage platform with a footprint of 406 m². The key advantage: increased operational capacity and storage zone by adding a second level – without constructing a new facility.
This extra level maximized storage density, enabled safe and quick access to goods, and unlocked the full potential of the warehouse capacity.
Smart control through HMI – real-time insight and flexibility
The automated conveyors run on our in-house control technology and WXS software. Fully integrated with the customer’s WMS, the equipment determines the route and drop-off point for each pallet. Intuitive HMI touch panels allow operators to track equipment status, monitor workflows in real time, and respond instantly to changes – minimizing downtime and human error. The synergy between automated equipment and software enables the pallet warehouse to easily adapt to seasonal peaks and scale production on demand.
KAPELOU pallet equipment and technology used:
- vertical pallet conveyor;
- driven roller conveyor for pallets;
- pallet receiving section;
- custom-built storage platform.
Results. In close cooperation with the customer, we implemented fully integrated logistics automation technologies that helped to increase warehouse capacity and expanded the operational footprint and pallet storage zone.
Key benefits delivered:
- automated inter-level pallet handling;
- up to 60 pallets/hour throughput;
- +406 m² of usable pallet storage space without construction;
- real-time process and movement control;
- safe, ergonomic working environment.
We thank the customer for trust, collaboration, and commitment to advancing warehouse handling operations. Together, we built a pallet warehouse that runs with zero downtime, responds quickly to demand, and is ready to scale alongside the business.
Want to boost your pallet storage warehouse too? Get in touch – our engineers will design a technology tailored to the specific needs of your business.
