Logistics Warehouse Automation Case Study: Dixon International Logistics
Key Figures at a glance:
| Location | Dublin |
| Operational Time | 24 hours per day, 5 days per week (inbound 12 hours per day) |
| Throughput IN | 80 pallets per hour |
| Throughput OUT | 80 pallets per hour |
| Pallet Shuttles | 20 Moffett Automation Taxi pallet shuttles |
| Building Height | 16.6 metres |
| VTUs | 6 Moffett Automation VTUs |
| Inbound Locations | 6 |
| Outbound Locations | 6 |
| Special features | Retail storage for ambient and chilled products, two connected chambers, lowered floor section, client inspection area and solar-supported cooler system |
Moffett Automation delivered a temperature-controlled warehouse automation system for Dixon International Logistics in Dublin, connecting two storage chambers and increasing capacity to over 46,000 pallets.
Project Overview
Dixon International Logistics is a leading Irish temperature-controlled logistics provider based in Dublin. Established in 1979, the company specialises in ambient and chilled storage and distribution across sectors including food, pharma and retail.
As demand increased, Dixon International Logistics required a warehouse automation solution that could connect two existing storage chambers, maximise storage density and support efficient pallet movement across ambient and chilled operations. The project also required significant warehouse redesign, including strategic pallet positioning, lowered floor sections for conveyors and a dedicated inspection area for customer pallet review.
Moffett Automation designed and delivered a bespoke automated pallet storage system that increased total capacity to over 46,000 pallets, improved throughput and created a more scalable, energy-efficient warehouse operation.
Project objectives:
- Connect two existing storage chambers into one automated operation
- Increase pallet capacity beyond the original VNA layout proposal
- Support ambient and chilled temperature-controlled storage
- Enable PPT-friendly inbound and outbound handling
- Create a client inspection area for calling down specific pallets
- Reduce forklift dependency and manual handling
- Integrate with Dixon International Logistics new WMS
Challenges Presented
Dixon International Logistics faced several critical challenges in overhauling their warehousing operations:
Dixon International Logistics needed to connect two existing storage chambers so pallets could be transported efficiently to either area. The system also needed to maximise capacity under the angle of the roof, requiring strategic pallet positioning on the top level to make full use of the building.
The use of powered pallet trucks for inbound and outbound handling required major groundworks, including lowering sections of the warehouse floor so conveyors could be positioned correctly. Dixon International Logistics also required a dedicated inspection area where customers could view the system and call down specific pallets for review.
The system had to operate as a closed-door, lights-out storage area while supporting ambient and chilled products, customer-facing inspection requirements and full WMS integration.
A Connected Temperature-Controlled Automated Storage System
Moffett Automation delivered a bespoke automated pallet storage system designed around Dixon International Logistics two-chamber layout, temperature-controlled operations, groundworks requirements and customer inspection process. Installation began in December 2023 and was completed in June 2024.
Moffett Automation Taxi pallet shuttles
20 Moffett Automation Taxi pallet shuttles were deployed to move pallets efficiently between the connected storage chambers, operating reliably across temperature requirements from 2°C to 20°C.
Moffett Automation Conveyor
6 PPT-friendly reversible conveyors were installed, allowing each conveyor to be used for both inbound and outbound pallet movement.
Moffett Automation Racking
The racking system reached 18.5 metres in height across 8 levels, each with different pallet-height requirements. Pallet height is assessed at entry, allowing the system to store each pallet in the most efficient available location. The racking was also designed to support cooling platforms, reducing the need for additional warehouse structures.
Note: the page key figures say building height 16.6 metres, while the racking section says 18.5 metres. That needs checked and reconciled.
Moffett Automation VTU
6 Moffett Automation VTUs with dual entry on each level were introduced to optimise vertical pallet movement and maximise storage capacity.
Moffett Automation WCS
Moffett Automation WCS manages pallet storage, traffic control and route scheduling, integrating with Dixon International Logistics’ new WMS to support accurate inventory visibility and coordinated pallet movement from day one.
Project Results
The Moffett Automation system transformed Dixon International Logistics’ Dublin warehouse by connecting two temperature-controlled storage chambers and increasing capacity to over 46,000 pallets. This substantially exceeded the original VNA layout option, which would have provided approximately 26,000 pallet spaces.
The system supports 80 pallets per hour inbound and 80 pallets per hour outbound, with combined throughput of over 250 pallets per hour across both chambers. Using 20 Moffett Automation Taxi pallet shuttles, 6 Moffett Automation VTUs and reversible PPT-friendly conveyors, the solution improved pallet movement, reduced manual handling and eliminated forklift use in inbound and outbound processes.
The project also improved safety and operational control. Built-in redundancy allows Moffett Automation Taxi pallet shuttles to take alternative routes if a fault occurs on a specific route, reducing potential downtime. Safety wires, access controls and reduced personnel exposure to moving pallets created a more controlled warehouse environment.
The system also supports Dixon International Logistics sustainability goals. Combined with the efficiency of the cooler system and Dixon International Logistics’ rooftop solar generation, the automated storage operation contributes to a highly energy-efficient facility.
Assess Your Logistics Warehouse Automation Opportunity
Speak to Moffett Automation’s engineering team to review your logistics warehouse layout, pallet profile, storage constraints and throughput targets. We can identify where automated pallet storage could improve density, connect storage areas, reduce forklift dependency and support ambient or chilled operations.
