Smarter Vertical Lift Module Storage

In modern warehouses, space is becoming increasingly limited. This creates a constant challenge: how to store more goods safely while ensuring fast, accurate retrieval. But when saving space comes at the cost of performance, efficiency often suffers. That’s why leading logistics operators are turning to smarter, quieter solutions that not only optimise space but also enhance overall performance.

Setting a new standard for Vertical Lift Modules

One recent Megadyne customer set a clear objective: to develop a next-generation vertical warehouse capable of reducing occupied space by up to 90%, while maintaining the same storage capacity. Additional goals included lowering energy consumption and improving both speed and reliability during goods retrieval.

With nearly seventy years of experience in storage and material handling systems, the customer, a company specialised in designing and constructing vertical automated warehouses, turned to Megadyne to help optimise operations. Already in the design phase of a new solution, the OEM sought to reduce the footprint of vertical storage modules while enhancing operational efficiency.

The problem: chain drive limitations

The customer’s previous solution used chain drives to move shelves, a system that came with significant drawbacks:
• Excessive noise
• Dirt accumulation
• Constant lubrication requirements
• Limited precision
• Slower operating speeds
• Frequent maintenance needs

These issues disrupted operations, reduced uptime, and created a noisy, less efficient environment – far from ideal in high-performance warehousing.

Solution: The QST system

To overcome these limitations, the OEM partnered with Megadyne to implement the innovative QST (Quiet, Self-Tracking) System. A quiet, high-performance alternative to chains and standard straight-tooth profiles, the QST 14 M pitch is designed for heavy-duty applications requiring maximum torque transmission and durability, like warehouse automation.

The results were immediately evident: “This solution offered a significant reduction in noise levels, required less maintenance, and remained highly resistant to heavy loads. With high torque capacity and positive engagement in bi-directional movement, the QST technology provided the precision and speed necessary for optimal warehouse performance,” said a spokesperson.

Beyond boosting performance, this solution contributed to a quieter, cleaner, and more energy-efficient warehouse environment. What’s included in the QST System? The system includes belts, pulleys, and a clamp, all engineered to ensure optimal performance:
• Maximum compatibility
• Secure installation
• Minimal risk of operational errors

Download the full story: Delve into the full case study to explore how this high-performance solution set a new benchmark for vertical lift module systems.

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Food Producer to Implement Supply Chain Planning Solution

Finnebrogue, one of the UK’s leading and award-winning food producers, has selected RELEX Solutions, a provider of unified supply chain and retail planning solutions, to optimise supply chain planning across its four production sites. By implementing RELEX Supply Chain Planning, the family-owned business aims to improve production efficiency and maintain optimal inventory levels through demand sensing and planning, master planning, and production scheduling. RELEX partner, Supply Chain Company, will support the project with implementation services.

Renowned for its premium sausages and revolutionary ‘Naked Bacon’ and ham, made without nitrites, as well as its cutting-edge plant-based production facility, Finnebrogue is a leader in crafting exceptionally tasty and sustainable food from its operations in County Down, Northern Ireland. To further its commitment to operational excellence and sustainability, Finnebrogue is implementing an end-to-end supply chain planning software solution.

The goal: to create a unified, data-driven planning platform that reduces food waste, increases efficiency, and enables smarter decision-making across its operations in County Down. With over 500 SKUs and a diverse product portfolio, RELEX will support planning across Finnebrogue’s four sites – including its sausage and burger factory, bacon facility, cooked mushrooms and value-added, and its dedicated plant-based site.

“As a business driven by innovation and a passion for creating better food, we wanted a partner that could match our ambition,” said Dermot Hawkins, Operations Director, Finnebrogue. “With RELEX, we’re moving away from the limitations of complex spreadsheets and bringing demand, production, and materials planning together onto one integrated platform. This will improve efficiency, reduce risk and waste, and give us the insights we need to make faster, smarter decisions. RELEX’s proven expertise in food manufacturing made them the clear choice to support our journey toward more sustainable, streamlined operations.”

By adopting a machine learning–based demand planning solution with integrated demand sensing, Finnebrogue will gain a more accurate and real-time understanding of shifting demand patterns and consumer behaviour. This improved visibility will enable quicker responses to fluctuations, resulting in fewer lost sales due to improved product availability, better inventory turnover, and reduced waste, an especially critical benefit given the company’s focus on fresh products.

Additionally, advanced master planning and scheduling will allow Finnebrogue to optimise production across all four sites, ensuring efficient resource allocation and tighter alignment with actual demand. Together, these capabilities will enable the organisation to transition from spreadsheet-driven planning to a single, streamlined, and optimised planning environment, significantly improving overall operational efficiency.

“Supply Chain Company is delighted to bring our expertise to this project and support Finnebrogue in achieving their goals. Together with RELEX, we’re confident this collaboration will set a new standard for supply chain planning in the meat industry,” said Henk Jan Rijkse, Director, Supply Chain Company.

“We’re proud to welcome Finnebrogue, a company that shares our commitment to innovation and sustainability to our family,” said Stefano Scandelli, General Manager, Manufacturing Business Unit, RELEX Solutions. “Our unified platform will provide Finnebrogue with the visibility and control needed to optimise their entire value chain and also strengthen their position as a leader in sustainable food production.”

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End-to-end Automation with New Forklifts

Intralogistics specialist Linde Material Handling (MH) has expanded its range of automated forklift and industrial trucks, thus completing its updated product portfolio. A standout addition to the lineup is the automated Linde K MATIC k VNA turret truck.

“If customers are storing and retrieving exclusively full pallets in high-bay racking, this forklift eliminates the need for them to purchase a manually operated truck,” explains Pascal Kuster, Sales Trainer Automated Guided Vehicles at Linde MH. Other vehicles set to launch include the Linde R-MATIC k reach truck and the Linde L MATIC AC k counterbalanced pallet stacker with cantilevered forks. These series production models are designed to maximize the benefits of automation projects implemented with Linde MH, reducing planning and implementation times while ensuring greater efficiency and lower costs.

“With the new models, the already launched automated Linde L-MATIC HD k pallet stacker, and the fully automated compact Linde L-MATIC core variant, we can automate our customers’ material flow processes more easily and cost-effectively, while also making them more service-friendly and flexible for expansion,” says Kuster. The ‘toolbox’ that Linde MH’s automation planners use to develop these concepts includes high-quality, energy-efficient and easy-to-program AGVs and AMRs. “Our new vehicles play a key role in our automation solutions. However, good project planning and preparation are just as crucial to success,” Kuster emphasizes. “After all, our customers are investing in a solution, rather than just a product.” The standardization of processes is an essential prerequisite for any automation project. In this context, it’s important to note that processes with manual trucks cannot always be replicated one-to-one with the corresponding automated vehicle models. For example: If a reach truck operator was previously also responsible for transporting goods from the receiving area to the high-bay racking, in the automated system using an automated pallet stacker for this subprocess may be more efficient in order to increase throughput and optimize pallet-handling costs per hour.

A new generation of vehicles for efficient automation

The larger the product portfolio, the more options arise for developing automation solutions that are precisely tailored to customers’ specific needs. Linde MH capitalizes on this by offering the industry’s most comprehensive range of vehicles. The Linde K-MATIC k stands out in the premier league of warehouse technology. With a load capacity of 1.5 tons and a maximum lift height of 14.5 meters, this very narrow aisle (VNA) truck is designed to optimize warehouse capacity usage. “Since the truck primarily operates in rack aisles, using an automated vehicle is a sensible choice,” explains product trainer Kuster. “This allows employees to focus on higher value-added activities.”

The Linde R-MATIC k reach truck is ideal for automated replenishment in wide-aisle warehouse sections. Three models are available, with load capacities of up to 2.3 tons. To optimally customize the trucks for individual needs, they can be equipped with a wide selection of modular mast variants, offering maximum lift heights of up to 10 meters. Automated shuttle and storage solutions round off the extended range of vehicles.

Innovative technology boosts productivity

Both VNA trucks and reach trucks use state-of-the-art reflector technology for navigation. They feature a sensor-based pallet positioning system with “intelligent” forks for precisely storing and retrieving qualified load carriers such as Euro pallets, mesh boxes and CHEP pallets. The system not only detects whether a rack location is empty but also identifies any obstacles in the way. If pallets are not correctly aligned, the forks adjust accordingly. Furthermore, the system ensures that the goods are precisely positioned in the rack before the forks withdraw from the load carrier. The trucks are powered by either lead-acid batteries or the latest generation of lithium-ion batteries for maximum energy efficiency. Both battery types can be combined with all available manual or automatic charging options. A clear, colored touchscreen simplifies human-machine communication and makes entering control commands easier. Numerous standard features such as 360° scanners, emergency stop switches, lights and acoustic signals ensure maximum operational safety. Optional functions are available to supplement these features, including 2D curtain lasers and other lighting solutions such as BlueSpot and Red Warning Lines.

Integrated software platform MATIC:move

All new vehicles have been developed in-house and are designed to map key intralogistics processes end-to-end. VNA trucks and reach trucks are digitally networked with the pallet stacker variants. Automated trucks are controlled via the Linde MATIC:move (or MATIC:move+) software platform’s uniform user interface, which allows for real-time monitoring, display of open orders, predictive maintenance and standardized connection to WMS and ERP systems. Additionally, the Linde Warehouse Manager facilitates the networking of automated and manual vehicles and their integration into operational safety assistance systems such as the Linde Safety Guard. “However, cooperation with our customers is a key factor for success,” emphasizes Kuster. “We provide comprehensive support to decision-makers throughout the entire process, from the conceptualization phase through implementation. We assist in standardizing processes, defining key performance indicators and simulating material flow with the help of our digital twin. This approach ensures a solid foundation for successful project completion and a swift return on investment. And after commissioning, our experienced service technicians and the high density of our sales and service network ensure that customers can rely on fast response times for maintenance and repairs.”

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