Large-scale cold-chain logistics automation - Congelados de Navarra

Summary

Congelados de Navarra, a leading European frozen vegetable producer, has continuously grown since its establishment in 1998. The company partnered with Mecalux to enhance its logistics operations with automated cold storage solutions. Over several phases, Mecalux implemented state-of-the-art technologies such as automated Pallet Shuttle systems, stacker cranes, and Easy WMS software. The logistics centre now operates at optimal efficiency, with over 160,000 pallet capacity and fully automated processes. This partnership has enabled Congelados de Navarra to boost productivity, ensure product traceability, and stay at the forefront of the food industry with cutting-edge, intelligent automation.

Takeaways

• 😀 Congelados de Navarra is a leading European producer of deep-frozen vegetables, expanding to over 70 countries with a production capacity of 250,000 tonnes annually.
• 😀 The company has been partnering with Mecalux for warehousing solutions since its founding in 1998, including the installation of automated storage systems.
• 😀 The logistics center in Fustiñana, Spain, includes multiple phases of automation, including the installation of automated clad-rack warehouses with a total capacity of 63,000 pallets.
• 😀 The logistics center features twin-mast stacker cranes operating at -25 degrees Celsius, enhancing efficiency in cold storage operations.
• 😀 In 2017, the third phase introduced a packaging and mixing area, further improving the supply chain.
• 😀 The fourth phase, completed in 2019, included one of Europe’s largest automated freezer warehouses, with over 83,000 pallet capacity and Pallet Shuttle systems.
• 😀 Phase 5 brought an additional automated warehouse, increasing storage space and capacity for over 15,000 pallets, making the entire center’s capacity more than 160,000 pallets.
• 😀 Mecalux’s Easy WMS software manages the entire logistics center, offering full traceability of products from entry to dispatch and optimizing warehouse management.
• 😀 Easy WMS software integrates seamlessly with Congelados de Navarra's ERP and MES systems, coordinating goods flows, inventory management, and dispatch operations.
• 😀 The automated Pallet Shuttle system and transfer cars, along with high-density racking, ensure maximum capacity and a high flow of goods in the cold storage environment.
• 😀 The logistics center's operation is designed to maximize efficiency through automatic storage allocation, SKU management, and adaptable storage space optimization based on production demands.

Q & A

What is Congelados de Navarra known for in the European market?

Congelados de Navarra is a leading European producer and marketer of deep-frozen vegetables, with a presence in over 70 countries and an annual production of 250,000 tonnes.

How has Congelados de Navarra maintained its growth?

Congelados de Navarra has maintained its growth by prioritizing innovation through new technologies to meet market demands and satisfy customer needs.

What role did Mecalux play in Congelados de Navarra’s logistics operations?

Mecalux played a crucial role in outfitting Congelados de Navarra’s logistics centres with efficient technology solutions, including automated warehouses, stacker cranes, and the Easy WMS software to manage their operations.

What are some of the key features of the automated warehouses at Congelados de Navarra’s logistics centre?

The automated warehouses at Congelados de Navarra feature automated clad-rack systems, twin-mast stacker cranes, and the Pallet Shuttle system. They operate at a constant temperature of -25 degrees Celsius and manage a high flow of goods.

How does Mecalux’s Easy WMS software enhance Congelados de Navarra’s logistics efficiency?

Easy WMS software optimizes the management of the logistics centre by offering full traceability of products, coordinating pallet movements, and managing various warehouse functions simultaneously, including storage, relocation, and dispatch.

What changes were made in Phase 4 of the logistics centre?

In Phase 4, Mecalux expanded Congelados de Navarra's centre by building an automated warehouse with a Pallet Shuttle system, significantly increasing storage capacity to over 83,000 pallets and improving the flow of goods and automated processes.

What makes the Pallet Shuttle system at Congelados de Navarra’s warehouse innovative?

The Pallet Shuttle system allows for high-density racking and ensures a high flow of goods with simultaneous entries and exits. It maximizes storage capacity and eliminates errors from manual handling.

How does the shared channel with variable depth in the Phase 4 warehouse work?

The shared channel with variable depth stores two different SKUs in the same channel, optimizing storage. The quantity of each SKU is managed by Easy WMS software, either automatically or manually, to ensure efficient use of space and timely order fulfillment.

What was achieved in Phase 5 of the logistics centre development?

Phase 5 involved setting up an additional automated warehouse with capacity for over 15,000 pallets, expanding the total storage capacity to over 160,000 pallets across four automated warehouses.

How does the logistics centre handle high volumes of outbound goods?

The logistics centre efficiently handles high volumes of outbound goods through interconnected conveyors, transfer cars, and dispatch zones, with around 100 lorries dispatched daily and goods being moved seamlessly between warehouses and the packaging area.