COSGRA
Electronics Warehouse
>40%
increase in storage density
5,104
storage locations optimized for efficiency
2,700
SKUs efficiently managed in an automated system
81 totes/hour
throughput capacity
ULMA Handling Systems is a trusted global provider of industrial automation and intralogistics solutions. Drawing on decades of experience, ULMA offers end-to-end solutions that improve efficiency and drive innovation in warehouse operations across various industries.
Instalux Soniger specializes in designing and installing customized industrial storage solutions. With extensive expertise in conventional racking systems and a strong focus on warehouse optimization, Soniger ensures seamless integration with advanced automation technologies.
COSGRA
COSGRA, a leading provider of industrial solutions specializing in electric motors, power transmission systems, and mechanical seals, operates from their facility in Girona, Spain. Designed for versatility and efficiency, the facility includes a dedicated workshop for repairs and maintenance, a spacious storage area for bulky items, and a specialized section for smaller items, picking, and packing orders. This infrastructure supports COSGRA’s ability to deliver high-quality products and services with precision and reliability to clients across Spain and beyond.
With a rapidly growing inventory and increasing international demand, COSGRA required a scalable logistics solution that could optimize storage, streamline operations, and support future growth.
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Balancing Storage Density with Cost Efficiency COSGRA required a solution capable of maximizing vertical and horizontal storage capacity within its existing facility, ensuring cost-effective operations.
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Streamlining Operations Across Systems The integration of automated and manual workflows demanded seamless communication between diverse systems to ensure operational harmony.
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Customizing Racking and Tote Handling COSGRA’s unique inventory requirements and specific tote dimensions required a tailored approach to racking design and robotics compatibility.
The Facility Before & After
Hai Robotics, ULMA Handling Systems and Instalux collaborated closely with COSGRA to deliver a tailored automation solution:
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High-Density Storage with HaiPick Robots:
Deployed 3 HaiPick A42TD-G-E1 telescopic, double-deep robots capable of double-deep stacking, significantly increasing storage capacity in both vertical and horizontal dimensions.
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Streamlined Conveyor Interface:
A single conveyor-supported station, designed by ULMA, enabled efficient material flow and seamless robot integration while minimizing infrastructure costs.
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Tailored Solutions for Specialized Needs:
Custom-designed racking systems, installed by Instalux Soniger, were engineered to integrate seamlessly with Hai Robotics’ ACR system and to accommodate COSGRA’s unique tote dimensions (600x400x120 mm), ensuring maximum storage density and system functionality.
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Seamless System Integration:
Hai Robotics’ ESS GreyBox system facilitated smooth communication between COSGRA’s warehouse management system, ULMA’s conveyor network, and the robotic solution, creating a cohesive and efficient intralogistics process.
The system was fully deployed and has been operational since Q3 2024, marking a successful milestone in COSGRA’s automation journey.
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