Robots, shuttles, and conveyors – a modern warehouse solution

The KAPELOU team delivered a modern turnkey automation project covering all warehouse zones, from receiving to shipping. Robots, shuttles, and conveyors were integrated into a single system with custom-developed software.

Automated receiving – accuracy and reliability

To ensure precise stock replenishment, we implemented an automated receiving line. Products are scanned, quality-checked, and counted. Items are transferred from pallets into totes, then transported via conveyors to their designated storage zones.

Mezzanine pent vertical logistics

To maximize the existing storage area, a three-level, 1,350 m² mezzanine platform was installed. High-demand items are stored on the first level, accelerating order fulfillment and delivery.

Key advantages of the mezzanine platform:

• expanded storage capacity – maximized warehouse space efficiently without physical expansion;
  
• optimized layout for sorting, packing, consolidation, and storage zones;
  
• free movement for staff and equipment on the ground level;
  
• scalable infrastructure – additional racks can be added to accommodate new product lines or increased volumes without downtime.

Conveyor system – modern, fast, precise, and reliable warehouse equipment

A loop conveyor system on the first warehouse level ensures continuous movement of totes, forming the backbone of the automation.

Modern warehouse benefits:

• continuous product flow – totes move automatically between zones;
• faster product handling through integration with shuttle systems;
• accelerated order fulfillment – vertical conveyors transport items from different warehouse levels without delays;
• automated return of empty containers;
• reduced manual operations.

Picking zone optimization – high warehousing throughput with zero errors

The storage area features two warehousing buffer-sequencers: one accumulates picked items ready for dispatch, and the other – a shuttle system – stores and processes high-turnover SKUs and packed orders.

Urgent orders are processed via high-speed AGVs. After packing, containers are routed by a Pick-to-Light system onto powered roller conveyors heading to the shipping area. Planned orders use the warehousing AS/RS GNOM system, then spiral conveyors deliver packed orders to the shipping zone.

Weight module – accurate order fulfillment and shipping operations

Each order is verified at the warehouse shipping zone. The weight module compares the actual item weight against the system record; discrepancies redirect the item to the warehousing reject zone. Packed orders are automatically strapped for secure transport. A 16-chute diverter sorter handles up to 1,000 packages per hour, ensuring smooth dispatch.

Automated operator workstation – real-time monitoring and control of warehousing operations

An interactive operator panel monitors all warehouse zones, equipment levels, and key parameters in real time. Continuous warehousing equipment monitoring ensures seamless operation and high throughput at every stage.

Modern warehousing equipment and technologies used:

• buffer-sequencer;
• shuttle system;
• AGVs;
• Pick-to-Light;
• powered roller conveyors;
• AS/RS GNOM;
• spiral conveyors;
• weight module;
• strapping machine;
• diverter sorter.

Results. After full automation, the customer’s warehouse operations are faster, more accurate, and more efficient:

• productivity increased to ~39,000 orders per month;
• uninterrupted material flow;
• productivity up to 150 SKUs/hour per operator;
• automated warehousing storage placement;
• high-density warehousing storage zones;
• parallel and prioritized processing of urgent and scheduled orders;
• reduced manual operations.

We sincerely thank OMEGA for the trust and collaboration. Together, we created a modern warehouse, laying the foundation for scalable growth.

What is modern warehousing? It means using advanced technologies and innovative methods to ensure efficiency, flexibility, and scalability in warehouse logistics operations.