Maximised Storage Capacity for Leading Packaging Provider Total Packaging
Key Figures at a glance:
| Location | Netherlands |
| Operational Time | 24 hours per day, 5 days per week (inbound 12 hours per day) |
| Throughput IN | 33 pallets per hour, with peak inbound capacity of 66 pallets per hour |
| Throughput OUT | 16 pallets per hour outbound, constant |
| # Taxis | 4 Moffett Automation Taxi pallet shuttles |
| Building Height | 12.2 metres |
| VTUs | 2 Moffett Automation VTUs |
| Inbound Locations | 2 |
| Outbound Locations | 2 |
| Special features | CO₂ fire safety requirements, hazardous goods regulation considerations, specialised conveyor/fire door interfaces and future throughput scalability |
Moffett Automation delivered an automated pallet storage system for Total Packaging, designed around WMS integration, CO₂ fire safety requirements and compliance considerations linked to hazardous goods regulations.
Project Overview
Total Packaging is a Netherlands-based packaging solutions provider that designs, develops and produces packaging across folding cartonage, wrapping cartonage, vacuum forming and fulfilment. The business serves a diverse customer base, including the home and body cosmetics sector, and required a storage solution capable of handling varied SKUs, batch sizes and operational requirements.
Moffett Automation partnered with Total Packaging to deliver an automated pallet storage system that improved storage density, streamlined pallet movement and integrated with the customer’s existing WMS logic. The project also required careful design around CO₂ fire safety requirements and compliance considerations linked to hazardous goods regulations.
The result was a bespoke automated storage solution designed to improve capacity, safety, operational control and future scalability within a complex packaging warehouse environment.
Challenges Presented
Designing Automation Around Fire Safety, Compliance and SKU Complexity
Total Packaging required an automated storage system that could maximise pallet capacity within defined spatial constraints while handling a diverse mix of packaging products, SKU profiles and batch sizes. The system also had to work with the customer’s existing Auto VNA WMS logic, creating a need for carefully planned software integration.
The project involved specific design requirements linked to CO₂ fire safety and hazardous goods regulation compliance. These requirements influenced the design of specialised conveyors at fire safety doors, customised inner walls and racking anchors. The system therefore had to deliver storage efficiency while fitting safely into a tightly controlled building and compliance environment.
Storage Transformed
A Bespoke Automated Storage System for a Complex Packaging Environment
Moffett Automation developed a bespoke automated pallet storage system for Total Packaging through a detailed collaborative design process. As building and compliance requirements evolved, Moffett Automation adapted the system design to align with the customer’s fire safety, WMS integration and operational requirements.
Moffett Automation Taxi pallet shuttles
4 Moffett Automation Taxi pallet shuttles were installed to move pallets efficiently through the automated storage system and support precise storage and retrieval across the warehouse layout.
Moffett Automation Conveyor
The conveyor system was designed to integrate with specialised fire safety doors and existing warehouse infrastructure, supporting controlled pallet movement into and out of the automated storage area.
Moffett Automation VTU
2 Moffett Automation VTUs were introduced to optimise vertical pallet movement and improve use of the available 12.2-metre building height.
Moffett Automation WCS
Moffett Automation implemented warehouse control software to manage pallet storage, traffic control and route scheduling. The software was adapted to integrate with Total Packaging’s existing WMS logic, simplifying system interaction while supporting peak inbound volumes of up to 66 pallets per hour.
Safety and compliance measures
The project included fencing, light curtains and system design measures linked to CO₂ fire safety requirements, fire door integration and hazardous goods regulation compliance considerations.
Technical online support
Moffett Automation provides 24/7 remote technical support from its in-house team to help maintain system availability and respond quickly to operational issues.
Local mechanical support
The Moffett Automation system is supported by a local service partner providing preventative maintenance and rapid 24-hour on-site response when required.
Project Results
The Moffett Automation system helped Total Packaging increase storage efficiency and operational control within a complex packaging warehouse environment. The automated storage solution improved pallet density, supported variable SKU and batch requirements, and integrated with the customer’s existing WMS logic.
The system was designed around specific CO₂ fire safety requirements and hazardous goods regulation compliance considerations, including specialised conveyor interfaces at fire safety doors, customised inner walls and racking anchor requirements. This allowed Total Packaging to improve warehouse automation while maintaining the required safety and compliance framework.
The system supports 33 pallets per hour inbound, with peak inbound capacity of 66 pallets per hour, and 16 pallets per hour outbound. The software integration simplified interaction with Total Packaging’s WMS and improved system management. The solution also confirmed future scalability, including the potential for AGV integration and increased throughput as operational demand grows.
By combining automated pallet movement, WMS logic integration, fire safety design and future scalability, Moffett Automation delivered a robust automated storage platform tailored to Total Packaging’s packaging production and fulfilment requirements.
Assess Your Packaging Warehouse Automation Opportunity
Speak to Moffett Automation’s engineering team to review your warehouse layout, pallet profile, SKU complexity, compliance requirements and throughput targets. We can identify where automated pallet storage could improve density, flow, safety and operational control.
