In addition to the fully automated warehouse and picking solution called Order Picking Machinery (OPM) for dry goods, Witron Logistik + Informatik GmbH from Parkstein, Bavaria, will also provide this technology as General Contractor for the complete fresh and frozen goods section. In two different respects, this project order is an absolute novelty for the Parkstein automation experts: For the first time, Witron is to realize a project of such extent on Spanish premises. On the other hand, Witron will – for the first time - integrate the fully automated warehouse and picking solution OPM into the dry as well as the fresh and frozen goods section.

Mercadona follows a strategic expansion plan that considers not only the continuously increasing number of outlets, but also the expansion of the company-wide logistics resources. Efficiency analyses preliminary to the planning of the new warehouse location showed that the fully mechanization of the local warehouse in Ciempozuelos would have significant advantages compared to conventionally operated warehouse centers. Mercadona therefore decided to fully automate the local warehouse based on the warehouse and picking system OPM designed by Witron.

Absolute Novelty: Fully automated picking of fresh and frozen goods by means of OPM

With OPM, Mercadona is investing in one of the most innovative warehouse and picking solutions that allow the automatic picking of dry goods as well as fresh and frozen goods. The fresh and frozen goods center is subdivided into three temperature zones (+12°C, +3°C and -23°C). An automatic tray warehouse featuring 237,000 locations and 46 stacker cranes plus a 12-aisle high-bay warehouse (HBW) for 8,600 Euro pallets will be integrated for the temperature controlled storage areas alone. For the fully automated picking process that can reach a pick performance of 220,000 totes or cartons at peak days, Witron will utilize 8 automatic layer depalettizers and 23 COMs (Case Order Machines). This corresponds to approx. 3,600 order pallets.

Dry goods retail units will be buffered in a second automatic tray warehouse by means of 32 aisles on 265,000 locations. The replenishment of this picking buffer will be carried out fully automatically from a high bay pallet warehouse - HBW (length 103 m, width 80 m and height 18 m) featuring 20 stacker cranes and 20,400 pallet locations. A total of 16 mechanized picking machines (COMs) will assemble up to 5,900 order pallets at peak days fully automatically and that corresponds to approx. 155,000 retail units.

Besides the picking of individual trade units and the full pallet handling, Witron will realize a further system highlight in the distribution center in Ciempozuelos that can also pick semi and quarter pallets fully automatically. PS2M (Pallet Storage Stacking Machinery) as it is designated by Witron, means the picking function that is directly integrated into the replenishment HBW of the dry goods area. PS2M picks different semi and quarter pallets fully automated and customer oriented onto a dispatch pallet.

Small articles and products that cannot be picked fully automatically will be picked in special picking areas that will be integrated in the system. Witron will use the proven tote picking solution Dynamic Picking System, DPS, with 250 dynamic and static pick channels and additionally 360 rack pick locations. Large-volume and bulky goods like e. g. bagged goods are picked in a separate pallet pick area on the basis of the Witron Module Picking System (MPS). Both systems work with Pick-by-Light-Technology and constitute a combination of “Goods-to-Man-Principle” and “Man-to-Goods-Principle”.

The steel construction for the automatic tray warehouse and the replenishment HBW for dry goods started at the end of March 2005. From June 2006 onwards, this system part will be ramped up step by step until a maximum of 5,900 order pallets with dry goods will daily leave the distribution center in Ciempozuelos. The automation of the fresh and frozen goods area will start in November 2005. Ramp-up for this part is planned for January 2007.

The food retail chain Mercadona with 862 (status 2004) stores and a yearly turnover of more than 8.770 million Euro (2004) is the leading and most expansive company in this branch in Spain. Mercadona employs more than 52,000 staff members. Mercadona annually opens at an average 100 supermarkets that cover not only groceries from a wide product range, but also goods from a full product range like e. g. care and drugstore products. Two of the company’s substantial maxims are the high product quality of the assortment and the price policy. Mercadona offers to its customers high quality products at attractive prices, since these can be ordered directly from the manufacturer without any added margins of distributors.