To accommodate increasing material volumes without expanding its warehouse footprint, ITECA replaced its predominantly horizontal storage system with an automated vertical storage solution.
The project involved the installation of two Vertimag® 103 XL vertical lift modules, each standing 10.26 meters high, designed to maximize available vertical space and centralize component management.
Together, the two systems provide 120 trays, offering approximately 525 m² of storage surface within a combined footprint of just 34.8 m².
Each VLM features 60 trays with a load capacity of up to 990 kg per tray and an Ergo-Tech® internal picking station, designed to facilitate loading and unloading while improving workstation ergonomics.
Thanks to the goods-to-person principle, operators no longer need to walk through the warehouse to retrieve components. Instead, the automated storage system delivers the required trays directly to the picking station.
This transformation has enabled ITECA to optimize operating times, reduce unnecessary operator movement and improve workplace health and safety, making everyday material handling more efficient.
ITECA’s challenge extended beyond storage capacity. The company also needed to manage increasing volumes of components and accelerate material flows supporting the production of food processing machinery.
Although ITECA already had an established logistics organization, introducing vertical lift modules represented a significant step forward in the way warehouse operations were managed.
To improve material visibility and control, both Vertimag® systems were connected to the company’s enterprise management environment, allowing operators to interact with the automated storage units through a software communication interface.
The system enables operators to monitor warehouse status, automatically retrieve trays and coordinate picking activities based on picking lists generated directly by ITECA’s ERP system.
The configuration also includes laser pointers and alphanumeric LED displays, which help operators identify the correct items during picking and replenishment.
By integrating vertical automation with the enterprise management system, ITECA can improve picking speed and accuracy, centralize material control and reduce manual handling activities. The result is a more structured, digitalized internal logistics process capable of supporting the company’s continued production growth.
For a manufacturer of customized industrial production equipment, component availability and efficient internal material flows are essential to maintaining production continuity.
By introducing Vertimag® vertical lift modules, ITECA achieved its main project objectives: optimizing storage space, improving material management and accelerating picking and sorting operations.
According to the company’s testimonial, the transition to a goods-to-person system has delivered significant time savings, lower operating costs and improved workplace ergonomics and safety.
The project also establishes a foundation for further technological developments. ITECA is exploring intelligent tray management, predictive analysis of warehouse material flows and additional digital solutions to improve operational efficiency and sustainability.
Vertical warehouse automation therefore provides a scalable foundation for industrial production growth, combining space optimization, process digitalization and a people-centered approach to workplace safety.
| Installed systems | 2 Vertimag® 103XL990-BIG H10261 |
|---|---|
| Footprint per unit | 17.40 m² |
| Storage surface per unit | 262.65 m² |
| Useful storage volume | 115.56 m³ |
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Ferretto Group S.p.a.
Strada Padana verso Verona, 101
36100 Vicenza, Italy
DIN./VAT.N IT00149440240
C.S. EURO 5.000.000 i.v.
