SAICA improves customer service with Pesmel automated roll warehouse

Pesmel will supply the world’s largest paper mill rack-type automated roll warehouse (ARW) to SAICA Paper’s El Burgo de Ebro mill located near Zaragoza in Spain. This mill produces board grades 1,300,000 tons annually using three paper machines. The new ARW will also store and distribute rolls from SAICA’s Zaragoza mill.

This TransRoll storage will be erected right after the PMs in two phases in the middle of ongoing mill production. The existing manual clamp truck-operated warehouses will be torn down to make space for the new automated TransRoll storage. A temporary storage will be erected adjacent to the existing warehouse in order to maintain the storage capacity during the construction period. Phase 1 production start-up will be Q1/2019, and Phase 2 is planned to follow after that. Total storage volume after both phases have been commissioned will be 70,000 tons.

“The need for automated storage concepts in paper mills, both as intermediate roll storages between different production stages and as shipping distribution centers, is growing strongly. The simple reason for this is the industry’s shift from bulk production to more diversified production, and the need to respond to customer orders within days instead of weeks. Pesmel’s Material Flow concept offers perfect tool for this strategic change,” says Kaj Fahllund, Vice President of Pesmel’s paper business.

TransRoll concept selected

The heart of this new system layout is Pesmel’s TransRoll automated roll warehouse (ARW) concept, which has many in-out connections at different floor levels between the mill production and shipping operations. Production happens 24/7 and is in random order as it comes in from production, and distributes it out to 6 + 6 truck loading stations according desired truckload combinations. On an average day 200 – 250 trucks will visit at the loading docks. Truck arrival happens in random order, and system guarantees truck specific load ready to be loaded within 20 minutes after the truck reports to the mill gate.

The whole footprint of this 70,000-ton warehouse will be only 10,000 m2 with 7 t/m2-high effective storing density. And at the heart of the mill’s material flow, the solution has whopping 1,000 t/h fully automated in-out handling and sorting capacity with four stacker cranes.

TransRoll ARW is equipped with a full Pesmel warehouse management system (WMS), which is connected to the MIS (mill information system) to track roll flow and to keep the real-time storage inventory for the converting and shipping operations.

For more information, please contact:
Mr. Kaj Fahllund, VP Paper & Converting
phone +358 207 009 626, email: kaj.fahllund@pesmel.com

Mr. Alberto Tainta, Saica Communication Officer
phone +34 976 103 100, email: Alberto.Tainta@saica.com

Pesmel:
Pesmel is global supplier of highly automated internal logistics, storing (AS/RS), and packing systems for the metal, paper and converting industries. Pesmel has delivered over 400 handling and packing projects and around 120 storage systems with more than 200 stacker cranes for four decades. The company employs over 200 professionals, of which about 120 are situated in Finland.

About SAICA
SAICA Group is a leading company in Spain manufacturing corrugated board with a capacity of 2.5 million tons of paper. The company currently has more than 9,000 employees in Spain, France, Italy, Portugal, the United Kingdom, Ireland, Turkey, Luxemburg, and The Netherlands. SAICA Group has four business areas: paper mills (Paper), collection of recyclable materials (Natur), corrugated paper pack containers (Pack), and flexible packaging (Flex). Consolidate sales of the Company are 2,378 million euros (as of 31.12.2015).
For more information, please visit www.saica.com