SMARTLOG DEPLOYS HYBRID PICKING AND CONSOLIDATION SOLUTION FOR MEBRA

Smartlog has implemented a comprehensive logistics automation project for Portuguese company MEBRA, a distributor of hardware and construction materials. The solution, rolled out at the Urretxu facility, integrates multiple order picking subsystems into a unified operational flow, enhancing efficiency in environments with high complexity and demand variability.

At the heart of the system is a hybrid picking architecture, combining a subsystem for heavy, low-turnover products with an AutoStore installation designed for small, fast-moving items. Both flows converge at a single order consolidation station, enabling simultaneous and synchronized order preparation from both systems.

The installed AutoStore system includes:

• 8 standard R5 robots
• 10,362 bins (330 mm height)
• Two carousel ports for picking
• One Transfer Cell port for inbound operations

This robotic system efficiently handles high-turnover items through autonomous robots that operate over a grid of stacked bins, automatically retrieving and depositing them as needed.

Simultaneously, MEBRA’s stacker crane subsystem has been upgraded through a retrofit process, involving the replacement of PLCs with commercial components, mechanical and electrical refurbishment, and the implementation of the new Galys management software, based on open-source architecture. The system is directly linked to AutoStore via a unique consolidation gantry, enabling simultaneous preparation of up to six orders, aided by pick-to-light indicators.

Another critical element of the project is the redesign of the conveyor circuit, which now transfers boxes from the stacker cranes to a new picking station located behind the AutoStore carousel ports. This configuration enables the consolidation of different product types on a single pallet and the automatic return of completed orders to the storage system.

The logistics design has been tailored to the spatial constraints of the warehouse while maintaining scalability. Thanks to the modular conveyor system and an additional AutoStore frame, the solution is prepared for future expansions to accommodate increasing volumes or new operational needs.

Among the challenges addressed were maintaining full process traceability, avoiding task duplication when consolidating different references, and adapting the system to fluctuating demand. The new setup enables MEBRA to significantly improve its operational efficiency without the need for physical expansion.

This project strengthens MEBRA’s capacity to serve both retail and horeca channels, ensuring high service levels through a flexible, precise, and scalable logistics operation.