Production of the capsules and sachets is almost uninterrupted, while distribution in contrast takes place in approximately two shifts over six days. Thus the central task is clearly defined: short-term buffering of products between production and distribution. So that production is not disrupted by a backlog in storage, the facilities in the advance zone and warehouse have to be extremely reliable.

All pallets are stored and retrieved on the first floor. The incoming pallets are weighed and their contours checked. The conveyor systems for connection with the local production lines are also located here.

The cartons leave the hygiene zone and are placed on wooden pallets on the production side. The pallets are delivered by rail from the production site at Orbe. The rail ramp is located right behind the high bay warehouse and is linked to the warehouse advance zone by an approximately 100m long conveyor line. While taking account of the client’s restrictive spatial guidelines, it was possible to integrate this line into the rack and it simultaneously acts as a welcome buffer for incoming product pallets.

The goods inwards conveyor technology on the ground floor only contains minimal conveyor technology so that the space stays freely usable. Pallets are dispatched with a stacker for transport into the warehouse. Incoming pallets are checked and weighed and transported immediately to the first floor for storage. Incorrect pallets are taken out of the flow on the ground floor into a reject zone. The article pallets are also retrieved for order-picking and Pick & Pack on the first floor. Order-picking for accessories takes place in the same room. Attention was paid to using the same conveyor technology for the flow of packaging material and empty pallets to optimize the spatial relationships.  

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