Mecalux outfits Moderna Products facility with pallet AS/RS

Intralogistics group Mecalux recently announced it has equipped Moderna Products’ warehouse in Izegem, Belgium with an automated storage and retrieval system (AS/RS) for pallets.

The system connects manufacturing with storage areas for unfinished and finished products as well as the order picking and shipping portion of the distribution center.

“We’re proud to say we manage the entire supply chain, spanning product development, production, storage, and distribution,” said Bart Bonte, Moderna Products owner and CEO. “Our priority is to use highly energy-efficient storage and production systems while maintaining our return on investment.”

Rack-supported storage warehouse holds up to 12,560 pallets

Moderna Products is a third-generation family-owned business based in Belgium - with a second production plant in South Carolina - that manufactures sustainable plastic injection molded pet products.

The company has automated the movements of 1,500 pallets a day with an energy-efficient rack-supported building. Measuring 131 feet high by 328' feet long, the facility constructed by Mecalux accommodates up to 12,560 pallets.

“Automation was the logical step. Our logistics processes had to align with the robotic advancements already underway in our production operations,” Bonte said. “We opted for automation to expand our space, enhance safety, and make our processes more environmentally friendly. As a result, we no longer require traditional lighting.”

Moderna Products said it is committed to eco-friendly and sustainable practices, having signed a Green Pact and equipped its headquarters with solar panels.

Mecalux’s automation system ensures the uninterrupted flow of goods between the center's various zones. Five twin-mast stacker cranes handle pallet movements inside the storage aisles and a conveyor system transports pet products to and from the manufacturing and picking areas.

WMS integrates production and distribution areas through AS/RS

Additionally, Moderna Products manages all operations with Easy WMS. The enterprise software monitors every step - from order receipt to shipping - providing complete control over the company’s internal supply chain.

Moderna Products has also installed the WMS for Manufacturing module to integrate the warehouse with the production lines and gain end-to-end traceability of its raw materials.

With automation upgrades in place, Moderna Products said it looks forward to continuing its commitment to caring for dogs and cats, which it has done since 1980.

The company will continue providing litter boxes, beds, carriers, feeders, and water dispensers for pets in over 79 countries worldwide. The company said it takes pride in “creating smart plastics for happy pets” sold under the MODERNA brand and private labels.

With the pet industry growing rapidly - projected to reach a value of $500 billion by 2030, according to Bloomberg - Moderna Products aims to double its sales in the next five years.

Want to learn more about robot and automation system integration? This article was featured in the December 2024 Robotics 24/7 Special Focus Issue titled “The process of robot integration.”