Clavo Food Factory has increased storage capacity and reduced operating times after implementing an automated logistics solution developed by Mecalux at its production facility in Tordesillas, Spain.
The company specialises in the production of ready-to-eat chilled and frozen food and produces 14,000 tonnes annually, supplying more than 42,000 restaurants worldwide with a portfolio of over 1,000 SKUs.
As demand for these products has grown, Clavo Food Factory faced increasing pressure to scale its operations while maintaining strict requirements for temperature control, traceability and efficiency. The company also needed to manage large volumes of raw materials and finished goods stored at subzero temperatures, without expanding its existing warehouse footprint.
To address these challenges, the company implemented a comprehensive intralogistics solution from Mecalux, combining an automated storage and retrieval system (AS/RS), Easy WMS warehouse management software and mobile racking.
Increasing capacity and improving efficiency
At the centre of the installation is Mecalux’s high-density 3D Automated Pallet Shuttle system, designed to maximise storage capacity and streamline pallet movements. The results have been significant. Clavo Food Factory has increased its storage capacity by 50% without expanding the footprint of the facility, while operating times have been reduced by approximately 20%.
“With the 3D Automated Pallet Shuttle, we’ve doubled our storage capacity, reduced idle time and lowered costs,” says Alejandro Lara, Plant Manager at Clavo Food Factory.
The system currently manages 5,827 pallets of raw materials and finished products, operating continuously to support production and distribution requirements.
Automation in a temperature-controlled environment
The automated warehouse operates at temperatures of up to -24°C, requiring reliable and efficient handling of goods under demanding conditions.
Inside the Mecalux system, a fleet of autonomous shuttles moves pallets across aisles and levels, changing height and direction as required. This coordinated movement ensures smooth and continuous operations while optimising storage density.
By automating pallet movements, the solution reduces manual handling in a cold environment and improves operational consistency.
From manual processes to digital control
Before implementing the new Mecalux solution, pallet location management in the freezer warehouse was carried out manually. This required operators to identify available storage positions and manage inventory without real-time visibility. The introduction of Mecalux’s Easy WMS has transformed this process.
“Before, we assigned pallet locations manually. Now, the WMS assigns slots automatically, so we no longer need to search for available space,” explains Iñaki Frías, Logistics Manager at Clavo Food Factory.
Easy WMS provides full traceability of food products and complete visibility of stock at all times. Integrated with the company’s ERP system, it also allows incoming goods to be pre-allocated, improving warehouse organisation and reducing handling times.
“Easy WMS provides us with complete visibility of every pallet. It helps us anticipate demand, which improves accuracy and gives us peace of mind in daily operations,” adds Frías.
Streamlining order fulfilment
Automation has also improved order preparation processes. The system coordinates picking operations and pallet dispatch more efficiently, reducing unnecessary movements and improving workflow organisation.
For example, when an order includes both full pallets and items requiring picking, the system first generates the picking tasks and then completes the order with the remaining pallets. This structured approach reduces processing times and improves overall efficiency. As a result, the company can manage higher volumes of orders while maintaining service levels and operational accuracy.
Optimising space and energy use
The high-density design of the Mecalux automated system enables more efficient use of available space, which is particularly important in temperature-controlled environments. By increasing storage capacity within the same footprint, the company reduces the need for additional warehouse space while improving internal logistics flows. In addition, optimised pallet movements and reduced handling contribute to more efficient energy use in the freezer warehouse.
Continuous operations and improved service
The integration of Mecalux automation and warehouse management software has enabled Clavo Food Factory to operate with continuous processes, supporting production and distribution activities more effectively.
“Our customers are already noticing faster service, and we can now handle a higher volume of operations,” says Alejandro Lara.
Automation has also contributed to improved internal organisation, helping streamline workflows and optimise the layout of the facility.
Supporting future growth
The modernisation of logistics operations at the Tordesillas plant represents a key step in Clavo Food Factory’s growth strategy. By combining automation, digital control and high-density storage, the company has created a more efficient and scalable logistics operation capable of supporting increasing demand.
The project also reflects the company’s commitment to innovation as a driver of competitiveness in the food industry, where operational efficiency and product traceability are critical. Following the implementation of the new system, Clavo Food Factory has improved efficiency and agility across its supply chain, enabling it to respond more effectively to demand peaks and support its continued expansion in international markets.
