Formation and Development

Founded in 1987 in Italy, Modula specializes in providing automated warehouse solutions, with the Modula Lift system standing out as a key innovation. This solution helps save space, accelerate goods handling, and enhance inventory management accuracy.

With over 30 years of experience, Modula has established an extensive distribution network, ensuring rapid customer support in multiple regions:

• Europe: Italy, Germany, France, the UK, Spain, Denmark
• North America: The United States, Canada, Mexico
• Asia: China, India, Singapore, Vietnam
• South America: Colombia

This network allows Modula to maintain its industry-leading position, offering cutting-edge smart warehouse solutions and professional after-sales services.

How Does Modula Smart Warehousing Work?

Since 1987, Modula has been designing and constructing automated warehouses to enhance intralogistics, ensuring superior storage quality and cost-effective picking operations.

Everything is based on the "goods-to-man" principle, where products are delivered directly to the operator rather than requiring the operator to move towards the goods, as seen in traditional shelving warehouses.

The Modula vertical warehouse operates similarly to an elevator. The operator, using the Copilot control panel, commands the retrieval of required goods. The smart warehouse then precisely locates the tray containing the requested items and automatically delivers it to the designated bay.

With trays capable of carrying up to 990 kg, the Modula vertical warehouse efficiently stores spare parts, products, packages, and bins. This system saves up to 90% of floor space and improves the safety of both goods and operators.

With Modula smart warehouses, there is no need for ladders, mezzanines, stools, or trolleys. Instead, operators can select the items they need with a single click and receive them within arm’s reach.

This solution not only reduces strain and fatigue during order retrieval but also eliminates workplace safety risks while optimizing inventory accuracy and resolving challenges related to goods organization and storage.

Depending on the scale and structure of the facility, different warehouse options are available, with the most common being the Modula vertical warehouse and the Modula horizontal warehouse.

Types of Modula Smart Warehouses

1. General Features

Modula smart warehouses integrate seamlessly with all ERP systems. Built from steel and equipped with a central motorized module, the primary benefits include space-saving, organized inventory management, and reduced labor costs.

By connecting the Modula WMS software with enterprise management systems, users gain a comprehensive supply chain management tool. This leads to significant cost savings, improved efficiency, enhanced safety, and optimal hygiene standards. The intelligent software guides operators for accurate and fast picking, minimizing errors.

2. The Modula Horizontal Warehouse

For factories with low ceilings, the Modula Horizontal Carousel provides an optimal high-performance storage solution. The horizontal warehouse does not require significant ceiling height and is ideal for fast and continuous picking operations.

3. The Modula Vertical Warehouse

Modula vertical warehouse models include:

• Modula Lift
• Modula Slim
• Modula Next
• Modula Pallet

These systems store goods vertically, maximizing storage height. Additionally, the Modula HC horizontal conveyor warehouse is available for businesses with low ceilings that still require automated storage solutions.

The efficiency of Modula automated warehouses can be further enhanced by integrating various options that boost productivity, simplify order picking, and improve operator safety.

Modula Vertical Warehouse

1. Modula Lift

The Modula Lift is highly flexible, suitable for businesses of various sizes and industries. It accommodates a diverse range of products with different sizes, shapes, and weights.

Advantages of Modula Lift:

• Space-Saving: Frees up floor space, keeping the facility tidy and safe.
• Versatile Storage: Suitable for industrial products, semi-finished goods, spare parts, and more.
• Flexible and User-Friendly: Multiple models and designs, easily customizable.

As a leading choice for automated storage systems, Modula Lift adapts to various facility layouts with multiple configuration options.

Key Features:

• Advanced design for enhanced picking accuracy and efficiency.
• Dual delivery level, enabling simultaneous operation on two trays for faster order processing.
• External bay, allowing operators to use mechanical aids conveniently.
• Customizable configurations to meet specific business needs.

The Modula Lift can reach up to 16.1 meters in height and support up to 90,000 kg, ensuring safe, clean, and efficient material storage while saving up to 90% of factory space.

Modula Lift Tray Configurations:

Depending on usage needs, Modula offers various retrieval bay configurations:

• Single bay
• Double bay
• Internal bay
• External bay
• Opposite bay
• Displaced bay

With the dual delivery level, operators can work on two trays simultaneously (one tray inside the bay while the other is prepared for the next retrieval). Additionally, an external bay facilitates operations with mechanical aids such as forklifts, weightless cranes, or hoists. Picking operations can also be performed simultaneously from both sides of the warehouse.

Regardless of the industry, Modula allows storage of any product or spare part, accommodating various sizes, weights, heights, and volumes.

What Can the Modula Lift Store?

• Spare parts
• Small items
• Products for distribution or sale
• Finished and semi-finished products
• Tools, equipment, cosmetics, pharmaceuticals
• Electrical and electronic materials
• Mechanical components
• Boxes and more

Modula Lift Models:

• ME, ME-D, ME-DD (smallest models)
• MA, MA-D, MA-DD
• MC, MC-D, MC-DD
• MX, MX-D, MX-DD
• ML, ML-D, ML-DD (largest models)

2. Modula Slim

Unlike the Modula Lift, the Slim warehouse stands out with its compact design compared to other Modula warehouse models. It is specifically designed to optimize space and enhance warehouse operational efficiency.

The Slim model occupies only about 3m² of floor space with a depth of 1.6m. It offers a load capacity of up to 25,000 kg per tray, allowing for the storage of a wide variety of materials and products, from loose items, storage boxes, small tools, spare parts, and wire coils to containers, etc.

With its pre-assembled modular structure, relocation and installation take approximately 48 hours. The system integrates seamlessly with ERP systems via Modula WMS software. Its user-friendly touchscreen interface and simple control buttons make it easy for operators to learn and use.

High Flexibility:

• Adjustable tray height for flexible storage.
• Advanced lifting technology ensures smooth handling of unbalanced loads.
• Energy-efficient, with power consumption below 1.2 kW/h.
• Flexible power supply options: three-phase (400V) or single-phase (230V).
• Simple maintenance with a smooth transmission system.
• Various options: visual guidance, Put-to-Light, access control, dividers, tray partitions, etc.
• The trays can be equipped with additional dividers and partitions, allowing for highly flexible storage of materials with different dimensions.

3. Modula Next

The Modula vertical warehouse Next is designed to eliminate errors during item retrieval. Unlike many other automated warehouse technologies, Modula Next responds to commands from the control panel to bring the correct tray to the operator's working position, allowing access to only one specific compartment.

The system ensures that a tray only opens when the exact compartment to be retrieved is identified, completely eliminating the risk of picking errors. Essentially, this system functions like a vending machine, controlling access, retrieval, and restocking at any time.

With Modula Next, picking errors will no longer occur, even for very similar products with different barcodes or those stored in adjacent compartments. It also helps prevent theft, damage, or unauthorized movement of goods.

Key Advantages of Modula Next:

• Full control over item retrieval
• No more stockouts
• Reduced delivery frequency
• Lower carbon emissions
• No more delays in locating required items

4. Modula Pallet

Pallets are a common means of transporting goods in warehouses. However, traditional pallet storage and handling methods take up significant space and require forklifts. The Modula Pallet smart warehouse is an automated pallet storage solution that replaces conventional pallet storage methods.

How Modula Pallet Works:

The Modula Pallet system can handle standard pallets (1200 x 800 mm) or similarly sized boxes. When a pallet is placed in the loading bay, the system automatically measures its dimensions, weight, and determines the appropriate storage location.

A standout feature of Modula Pallet is its ability to retrieve individual items without moving the entire pallet, as goods can be accessed from the side windows of the loading bay.

Advantages of Modula Pallet:

• Space-saving: The vertical storage system maximizes warehouse height utilization and frees up floor space.
• Increased safety: Pallet lifting is performed at ground level, eliminating the need for forklifts or high-altitude operations.
• Enhanced operational efficiency: Pallets can be lifted automatically without requiring manual forklift operations.
• Flexible storage: Accommodates both pallets and packaged or loose goods.
• Seamless integration: Compatible with automation systems such as AMRs, AGVs, and roller conveyors.

The Modula Horizontal Warehouse (Horizontal Carousel)

If your facility has low ceilings but you still want to optimize your picking processes, the Modula HC is the ideal automated storage solution.

The Modula HC is an automated horizontal conveyor system comprising multiple bins rotating on stainless steel rails, delivering products to the operator's picking area based on the "goods-to-man" principle.

How Modula HC Works:

Horizontal conveyors can be used in groups, often referred to as "pods." Different configurations are available, including two, three, or four conveyors, depending on the business's needs.

While an operator retrieves items from one conveyor within the pod, the other conveyors rotate and prepare materials for the next retrieval. This minimizes operator waiting time and exponentially increases efficiency.

Highlights of Modula Horizontal Carousel:

• Up to 550 picks/hour per pod
• 99% error reduction – Visual guidance system ensures accurate identification and retrieval of items.
• Optimized warehouse space – High storage density.
• Ergonomic and safe design.
• Modula WMS software integration – Real-time inventory management, easy data access, and stock tracking.
• Fast ROI (6 - 18 months) – Improved efficiency, reduced operating costs, and quick profitability.

Special Solutions

Over the years, Modula has researched and developed "special solutions" tailored for industrial businesses that require storage of sensitive items such as electronic components, pharmaceuticals, or food products.

Additionally, fire-resistant and earthquake-proof safety systems have been developed to minimize damage caused by fires or seismic events.

Applications

1. Industrial Manufacturing

In manufacturing plants, efficiently managing materials, components, and tools is crucial. The Modula warehouse helps:

• Optimized storage of machine parts and components.
• Reduced retrieval times with automation.
• Enhanced worker safety by eliminating the need for ladders, mezzanines, stools, or trolleys.

2. Automotive and Spare Parts

The Modula warehouse is widely used in the automotive manufacturing and maintenance industry due to its ability to efficiently store spare parts such as engines, wheels, filters, electronic components, etc.:

• Efficient storage of vehicle components like engines, wheels, filters, and electronic parts.
• Optimized warehouse space for garages and repair workshops.
• Prevention of dust, humidity, and environmental damage.

3. Healthcare and Pharmaceuticals

In the healthcare sector, the Modula warehouse plays a vital role in storing medicines, medical instruments, and specialized equipment. Its applications in this field offer several benefits:

• Ensures proper storage conditions to prevent drug and medical supply deterioration.
• Smart tracking system for expiry date management.
• Fast access to necessary medical supplies, especially in emergencies.

4. Aerospace Industry

In the aerospace industry, the Modula warehouse helps store essential components such as engines, propellers, and avionics. Key applications include:

• Scientific storage of aircraft components for easy retrieval.
• Minimized damage risks through stringent storage conditions.
• Accurate inventory tracking for effective material control.

5. Retail and E-commerce

For distribution centers and e-commerce warehouses, the Modula warehouse provides a significant advantage with its fast storage and retrieval capabilities. Some applications include:

• Efficient inventory management, preventing shortages or overstocking.
• Faster order processing for improved customer experience.
• Reduced warehouse rental costs through optimized storage.

6. Mechanical and Supporting Industries

In mechanical enterprises, the Modula warehouse facilitates the storage of tools, materials, metal blanks, and production equipment. Common applications include:

• Organized tool storage for quick access.
• Accurate material management, reducing losses.
• Protection from humidity, dust, and environmental factors.

With its ability to optimize space, enhance work efficiency, and integrate smart technology, Modula storage systems have become an essential solution in many industries. Implementing this system helps businesses reduce costs, increase productivity, and improve inventory management quality.

If you haven't yet found the ideal smart warehouse solution for your business, our technical team is always ready to provide free consultation to help you choose the optimal solution.

Reference: Modula Smart Warehouse