the first hbwh for coca-cola hellenic bottling company

The company
Coca-Cola HBC Italy is the most important producer and
distributor of The Coca-Cola Company products in Italy.
Its plant in Nogara (VR) is the most significant covering
50% of the production and distribution volume in Italy.
The plant was expanded and the warehouse today covers
35,000 m2, including a new aseptic production line for
the beverages Powerade (sport drink) and Nestea (iced
tea). Following this expansion, the Nogara plant now
covers a total surface area of over 62,000 m2 and is a
European record in the Coca-Cola Hellenic Bottling Group
for production and storage capacity producing 500 million
litres of beverages a year.

The problem and the objectives
Conventional storage of aseptic beverages normally
requires sizeable ground space with considerably higher
costs, as the palletized products cannot be stacked on
top of each other because of their lower resistance. Given
the large-scale production at the Nogara plant, it would
have required 14,000 m2 storage space, seven times the
space the new warehouse of 2,000 m2 takes up. Another
challenge was to integrate aseptic product management
in the overall coordination of the other materials.
A dedicated shipping area was required from where the
trailer trucks could be loaded with aseptic product.

The solution and the results
As a whole, the logistic structure consists of 15 platforms to
load trucks that make small deliveries and 15 loading bays
for trucks that feed the large customer park of wholesalers
and the large-scale retail trade. In order to integrate the
existing distribution capacity, a new shipping area for aseptic
product loading was constructed, served directly from the
new automatic warehouse.
The new warehouse is composed of 2 stacker cranes with
double the normal depth and 23 metres high with a maximum
capacity of 900 kg, and 4 SVL shuttles at the top that connect
the warehouse entrances to production and shipping. The
plant was designed making allowance for future expansion
to 4 mini load stacker cranes and double the storage capacity
from the current 8,000 to 16,000 pallets.
The products come into the warehouse from production
through 2 loading bays fed by a lift truck capable of carrying
3 pallets at a time. The incoming flow from production is
35 pallets/hour. At the entrance to the warehouse all the
standard pallet conformity checks are carried out: weight,
shape and forkability.
The shipping area is served directly by the SVL system serving
3 groups of bays with flow rack for pallet accumulation (15
pallets per rack). The product is loaded onto trailer trucks following the JIT logic, thus shortening the truck waiting
time and reducing the space needed to prepare the loads.
The trucks are loaded from the side using triple-fork lift
trucks able to guarantee an outgoing flow of 65 pallets/
hour serving 2 trucks at the same time.
The exit bay for the aseptic product, which must be loaded
together with the other products, is managed in a dedicated
shipping area. Thanks to the SVL system, it takes less time
for the product to cross from the warehouse to the shipping