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Close Warehouse retrofitting: expanding the pallet buffer system
GIZEH is a leading European provider of customized packaging solutions for the food industry, producing approximately 4 billion food containers annually. With six production sites in Germany, Poland, France, Canada, and Slovenia, the company maintains a strong global presence.
GIZEH approached KAPELOU with a clear request: to optimize the existing buffer zone. A limited buffer capacity in the storage area was causing pallet congestion on the production floor, ultimately reducing overall throughput.
To address this, our teams collaborated on a retrofit concept with two key objectives:
- expand the buffer zone capacity without expanding the facility footprint;
- ensure stable conveyor system throughput.
Following an in-depth analysis of the request, KAPELOU developed a tailor-made technical solution to significantly increase the buffer zone – without any structural expansion.
Chain conveyor: the backbone of the warehouse modernization
Automated pallet handling is centered around integrating a chain-driven conveyor and a diverter into the existing transport line. Pallets coming from the wrapper are directed to the main storage zone by default. If that zone is full, the diverter automatically redirects pallets to an additional buffer area. This new conveyor segment accommodates up to 12 pallets. Once space becomes available on the main line, the system automatically returns the pallets from the buffer for further processing.
Seamless integration – one unified system
The most challenging aspect of the pallet flow optimization was the software and safety circuit integration. The task was not just mechanical – it required creating fully synchronized, uninterrupted logistics with harmonized control algorithms.
To install the diverter, our team carried out a targeted removal of just a minimal section of the existing roller conveyor – without compromising the system’s balance. The new equipment was then precisely integrated into the PLC infrastructure, with customized logic and real-time synchronization with pallet flow. All work was performed during active production, with no need to halt operations.
KAPELOU equipment used in the case study:
- chain-driven conveyor;
- roller-driven conveyor;
- diverter;
- control panel;
- safety fence.
Results. KAPELOU delivered a turnkey retrofit solution that seamlessly extended the buffer capacity using a chain conveyor system.
Pallet buffer expansion without warehouse expansion:
- +12 pallet positions: buffer optimization without increasing building size;
- continuous flow;
- 60 pallets/hour: stable and reliable throughput;
- full integration with the existing system, maintaining all safety standards.
Tobias Burgmer, International Sales, KAPELOU EU: “This case study clearly demonstrates the power of pallet logistics automation and the flexibility of system integration. A key success factor was adapting the software to manage reverse pallet movement and dynamic routing logic. All installation work was done without interrupting production – thanks to precision engineering and excellent teamwork”.
We sincerely thank GIZEH for their trust, openness to innovation, and partnership approach. Through close cooperation, we successfully modernized pallet handling system and took operational efficiency to the next level.
Ready to remove bottlenecks in your warehouse automation? Fill in the contact form and let’s transform your pallet handling challenges into competitive advantages – together.
