Spanish food manufacturer Clavo Food Factory has modernized its Tordesillas processing facility by implementing an automated 3D pallet shuttle system, increasing storage capacity by 50% without expanding its physical footprint, according to intralogistics specialist Mecalux.
Automation at Minus 24 Degrees Celsius
Operating in the frozen food sector presents strict challenges regarding energy consumption, temperature control, and traceability. Clavo Food Factory produces 14,000 tonnes of chilled and frozen ready-to-eat products annually, supplying more than 42,000 restaurants worldwide with over 1,000 distinct stock-keeping units, according to Mecalux. To manage this volume, the company integrated a high-density automated storage and retrieval system designed to operate in subzero conditions.
The facility’s freezer warehouse maintains a constant temperature of -24 °C and accommodates 5,827 pallets of raw materials and finished goods. Ten autonomous multi-directional shuttles navigate the storage lanes, shifting between levels to handle pallets automatically. Fleet management software developed by Mecalux coordinates the movement of the shuttles to maintain a continuous material flow.
Software Integration and Traceability
Logistical operations at the Tordesillas plant are managed through the Easy WMS warehouse management system, which connects directly with Clavo Food Factory’s enterprise resource planning platform. The software assigns storage locations automatically upon notification of incoming goods, eliminating manual slotting procedures.
According to plant management, the technology has altered daily workflows across the supply chain. “Before, we assigned pallet locations in the freezer warehouse manually. Now, the WMS assigns slots automatically, so we no longer need to search for available space,” stated Logistics Manager Iñaki Frías. Plant Manager Alejandro Lara noted that the system has doubled storage capacity, reduced idle time, and lowered operating costs.
Operational Improvements and Metrics
The integration of the 3D pallet shuttle system, Easy WMS, and Movirack mobile pallet racking has yielded measurable efficiency gains for the Spanish food producer:
- Operating Times: Overall operating and processing times decreased by up to 20%, according to logistics management data.
- Storage Capacity: Storage capacity increased by 50% within the existing physical boundary of the Tordesillas plant.
- Inventory Control: The system provides round-the-clock tracking for 5,827 pallet locations containing perishable goods.
Order fulfillment workflows now sequence picking tasks alongside pallet dispatch, allowing operators to assemble complex multi-pallet orders more efficiently. By automating these processes, Clavo Food Factory aims to support its ongoing domestic and international expansion while maintaining cold chain integrity.