Warehousing upgrade: transformation without reconstruction

Following a detailed joint analysis of pharmaceutical warehouse logistics, the KAPELOU and Ametrin teams designed a tailored solution that not only addresses immediate needs but also scales with the business. For each warehouse zone, we selected high-performance equipment and cutting-edge automation technologies to meet Ametrin’s operational demands and intralogistics growth trajectory.

Smart space zoning – a strategic approach to efficient intralogistics systems

Our Concept & Analysis Department conducted an in-depth study of existing warehousing logistics – material flow intensity, product types, warehousing volumes, and operational patterns. Based on this data, we developed a space zoning strategy that optimized warehouse functions, minimized walking distances, and significantly accelerated order processing.

Vertical warehousing logistics – maximizing every cubic foot

To optimize the warehouse footprint, we installed a mezzanine for warehousing – single-level platform covering the dispatch area with office and technical spaces. The intralogistics mezzanine optimizes both horizontal and vertical warehousing space without the need for reconstruction.

The 966 m² intralogistics mezzanine enabled:

• x2 increase in warehousing capacity;
• relocation of certain intralogistics operations to the upper level;
• full use of the warehouse’s vertical volume;
• simultaneous processing on both warehouse levels.

Organized pharmaceutical warehousing – faster order picking

We introduced a structured pharmaceutical warehousing system based on the ABC/XYZ principle – placing high-rotation items near picking zones and slow movers in more remote areas. This warehousing system shortened access times, sped up picking operations, and reduced physical strain on staff.

Integrated warehouse logistics conveyors – for intralogistics automation

We deployed our in-house engineered roller conveyor system for plastic totes up to 35 kg. By automating key intralogistics functions, the solution increases warehouse throughput and operational resilience. With a modular approach to intralogistics automation, the warehouse is now prepared for future expansion and increased process complexity. Warehouse logistics conveyors became the warehouse’s backbone, enabling intralogistics transformation:

• seamless, fast, and precise transport of goods between zones and levels;
• reduced handling costs;
• higher intralogistics throughput;
• implementation of a true Goods-to-Person workflow;
• less manual handling;
• safe staff and forklift access via lift-up conveyor sections.

Racking and conveyors – accelerated logistics

We implemented a streamlined order-picking flow using gravity racking on both the ground level and platform for fast-moving A-class items, and shelf racks for slower-moving B and C classes. Workers pick directly into totes, which then move via conveyor to quality control and packing zones. Smart warehouse logistics conveyors and structured shelving streamlined intralogistics operation, driving pharmaceutical warehousing efficiency. Smart integration of conveyors and shelving systems has redefined the logic of modern warehousing for pharma and medical devices. Automation of pharmaceutical warehousing and distribution processes reduces lead times, increases accuracy, and supports scalable growth.

Tailored workstations – built for comfortable intralogistics

On the platform, we built a dedicated QA and packing zone, optimizing workstations to support different loading scenarios and operator paths. After checks and packing, totes descend via a sloped, non-powered roller conveyor to the dispatch area. There, they’re consolidated with orders picked at ground level, sorted by delivery routes, palletized, and sent to the outbound dock. Each product is verified before dispatch to ensure accuracy.

KAPELOU equipment and warehouse technologies used in the project:

• single-level platform;
• powered roller conveyors;
• gravity (non-powered) roller conveyors;
• QA and packing workstations;
• gravity flow racking;
• shelving systems.

Results. This project, delivered in close collaboration with the client, redefined the pharmaceutical warehouse logistics – unlocking the full potential of every square meter. The integration of scalable intralogistics solutions lays the foundation for sustainable growth and quick response to fluctuating order volumes. The project enabled optimization of intralogistics workflows, from receiving and storage to picking, packing, and dispatch.

KAPELOU’s end-to-end solution delivered to client’s warehouse:

• x2 increase in storage capacity;
• automation of critical order fulfillment processes;
• smart warehouse space utilization – no reconstruction required;
• simultaneous operations across two warehouse levels;
• fast and accurate order picking;
• lower physical strain for staff;
• logistics scalability aligned with business growth.

This case is a clear example of how thoughtfully engineered automation of intralogistics processes – rooted in real business understanding – can boost speed, accuracy, and quality of warehouse zones while reducing labor and logistics costs. Advanced warehousing in the pharmaceutical industry enables high-throughput operations and full visibility into material flow.

We are sincerely grateful to the Ametrin team for their trust, transparency, and collaboration. Together, we built a technology-driven warehouse ready to meet today’s intralogistics challenges – and scale for tomorrow.

Want warehousing results like these? Reach out – we’ll show you how to take your warehouse logistics to the next level.