Mecalux upgrades Goya warehouse logistics

Goya, a distributor of Latin American food products operating across Europe, manages a high-volume logistics operation supplying approximately 4,000 points of sale throughout Spain. The company’s warehouse in Casarrubios del Monte, in the province of Toledo, plays a central role in this network, handling a broad product mix that includes tinned goods, beans, sweets, beverages, and snacks. As order volumes and assortment complexity increased, the site required higher storage density and faster pallet handling to maintain service levels.

Operational challenges and objectives
The main challenge was to expand storage capacity within the existing footprint while improving throughput and reducing handling errors. With more than 2,200 stock-keeping units to manage, Goya needed a system that could support rapid replenishment cycles without compromising accuracy. Improving logistics efficiency and ensuring reliable, predictable outbound flows to retail customers were key objectives.

Semi-automated pallet storage as the chosen solution
To address these requirements, Goya deployed a semi-automated Pallet Shuttle system supplied by Mecalux. The solution was selected for its ability to combine high-density storage with controlled automation, allowing pallets to be stored and retrieved quickly while maintaining operational flexibility. The system supports deep-lane storage, reducing aisle requirements and maximizing available warehouse space.

System configuration and deployment
The installation consists of five racking blocks, each approximately 8 m high, with a total capacity of around 3,000 pallets. Storage lanes reach depths of up to 33 pallets, significantly increasing density compared to conventional racking. Within each lane, a motorised shuttle operates autonomously to move pallets, accelerating inbound and outbound movements while minimizing manual handling. Mecalux supported the project through system design and integration, ensuring compatibility with Goya’s existing warehouse operations.

Measurable operational impact
By automating pallet movements inside the racking, the system reduced handling times and limited the risk of operational errors associated with repetitive forklift movements. The higher storage density enabled Goya to expand capacity without extending the building, while faster pallet flows improved responsiveness to store replenishment demands. Although no specific performance figures were disclosed, the configuration directly supports higher throughput and more consistent service levels.

Strengthening European distribution operations
With the upgraded warehouse infrastructure in Casarrubios del Monte, the European subsidiary of Goya Foods reinforced its logistics backbone to support continued growth. The semi-automated Pallet Shuttle system provides the technical foundation for reliable, high-density pallet storage aligned with the demands of large-scale food distribution.

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