Unlocking Additional Warehouse Capacity in an FMCG Plant Through Intralogistics Optimization

As part of a major operational expansion, the client faced growing pressure on warehouse capacity and internal logistics performance within an existing production facility.

Operating within a brownfield environment created significant constraints. Storage areas were approaching capacity limits while internal transport flows between production, storage, and dispatch were increasing in complexity and frequency.

Key challenges included:

• Storage bottlenecks: Existing warehouse infrastructure limited the ability to increase storage capacity within the available footprint.
• High transport frequency: Frequent internal transport movements created inefficiencies and congestion across key logistics corridors.
• Complex material flows: The interaction between production lines, intermediate storage, and finished goods handling required careful coordination to maintain operational stability.
• Limited expansion space: The brownfield environment restricted the possibility of traditional warehouse expansion, requiring alternative high-density storage solutions.
• Automation integration: Potential automation technologies needed to be evaluated without disrupting ongoing production operations.

The client therefore required a structured intralogistics assessment to identify capacity improvements, evaluate alternative warehouse concepts, and define an optimized logistics design supporting future operational growth.