How Volpak’s Lean Logistics Transformation is Shaping Smarter Packaging Operations

Revolutionizing Logistics at a Historic Packaging Plant

Volpak, a key player in flexible packaging solutions and part of the Coesia group, has undertaken a sweeping change in its intralogistics setup at its longstanding Barcelona facility. This transformation, completed within six months, introduces lean principles, automation technologies, and a data-driven approach to redesign processes. It stands out as one of the company’s most ambitious operational upgrades.

Riding the Wave of Growth with Smarter Logistics

The surge in demand for flexible pouches, prized for convenience and sustainability, has fueled rapid growth for Volpak. Alongside expanding production volumes, the internal logistics for parts and sub-assemblies faced mounting challenges, particularly in managing limited space and increased workforce needs. The crux was clear: adapt to higher complexity in logistics without sacrificing flexibility, quality, or efficiency within the existing plant footprint.

Shifting from Push to Pull for Dynamic Material Flow

A bold rethink of logistics saw Volpak move from a traditional ‘push’ system to a ‘pull’ material flow model. Instead of predetermined stock movements, materials now travel strictly based on real-time production demand. Two years ago, the company introduced autonomous mobile robots (AMRs) to ferry select components directly from warehouse to assembly lines. The current phase extends this concept with a fully automated warehouse synchronized with three AMRs feeding the production floor, ensuring materials arrive just-in-time, minimizing delays and excess inventory.

Tackling Spatial Constraints with Vertical and Multi-Level Solutions

The Barcelona facility’s multi-level layout posed distinct challenges for expansion and logistics flow. Volpak overcame this by integrating vertical conveyors, high-density racking, and multi-level transport pathways. This configuration establishes a continuous, multi-tier material movement system, drastically improving capacity and cutting down travel times inside the plant. Automated routing connects inbound goods, inspection, and assembly areas seamlessly, with intelligent conveyors and buffer zones orchestrating precise timing.

Prioritizing Parts with Smart Segmentation

Before redesigning operations, an in-depth audit of over 40,000 SKUs (stock keeping units) was carried out—categorizing parts through an A-B-C system based on frequency and movement. The strategy dedicates the high-throughput zones to ‘A’ category parts, which account for 80% of logistics activity, while less active items sit efficiently in deep racks. Automated storage now offers over 50% more capacity and scalability, ready to handle a broader SKU range. The AMRs operate right inside the racks, maintaining a high throughput within a compact footprint.

Building an Ecosystem for Lean Excellence

The new setup solidifies Volpak’s ongoing journey with Lean principles, complementing prior improvements in assembly and Just-in-Time operational designs. Materials preparation now follows a ‘one-piece flow’ system—production orders are assembled and delivered as complete kits, slashing wait times and ensuring teams get precisely what they need when they start work. This approach not only speeds up the process but also supports cleaner workflows, reduces manual handling, enhances safety, and uplifts worker efficiency.

Key Highlights of the Transformation:

• Six-month execution timeline with in-house leadership and digital expertise from Coesia.
• End-to-end integration of automation and lean methodologies.
• Multi-level warehouse design maximizing limited spatial resources.
• Intelligent, real-time tracking and routing of materials.
• Enhanced storage solutions boosting capacity by more than half.
• AMRs enabling precise, just-in-time material delivery.
• Streamlined ‘one-piece flow’ assembly kits optimizing production readiness.

Setting a Benchmark for Future Logistics Innovations

Designed and managed internally, with Coesia’s engineering and digital tools supporting the effort, this logistics system demonstrates a scalable and replicable model. It exemplifies how even space-constrained, multi-level facilities can achieve world-class efficiency through smart automation and lean logistics design. The new Barcelona framework aligns perfectly with future Industry 4.0 goals, positioning Volpak as a reference point for similar upgrades across the Coesia Group.

Why This Lean Logistics Upgrade Matters for the Industry and Beyond

Volpak’s journey underscores a critical lesson: logistics isn’t just about moving goods from point A to point B—it’s about doing so in ways that optimize space, time, and resources while maintaining flexibility to meet modern production demands. This has obvious ripple effects for the broader field of logistics, showcasing that automation and lean principles can unlock significant gains even in complex facilities. In a world where timely, reliable delivery is king, this transformation offers a blend of operational excellence and sustainable practice to follow.

Of course, while solid reviews and case studies highlight the importance and success of such initiatives, nothing quite beats the insight gained through personal experience. Platforms like GetTransport.com offer users the ability to test and benefit from trusted, affordable global freight and cargo transport services firsthand. Whether it’s managing office moves, shipping bulky goods, or coordinating international freight, the ease and transparency provided empower businesses and individuals to make informed decisions without breaking the bank or facing hidden hassles. Book your ride on GetTransport.com и убедитесь, что логистика может быть организована правильно.

Transforming Logistics: What’s Next?

While this transformation may not dramatically reshape global logistics overnight, it reflects an important shift towards smarter, leaner, and more automated operations. The ripple effects set by projects like Volpak’s provide inspiration and a practical roadmap for industries everywhere working to balance increased demand, limited space, and the need for efficiency. At GetTransport.com, staying up-to-date with such developments helps the platform anticipate market needs and continue delivering seamless, affordable shipping and freight solutions worldwide. Start planning your next delivery and secure your cargo with GetTransport.com.

Заключение

Volpak’s intralogistics overhaul marries lean manufacturing principles, automation, and detailed data segmentation to craft a highly efficient, scalable warehouse and production environment. The transition from push to pull flow, the intelligent use of autonomous mobile robots, plus vertical storage innovations collectively demonstrate how complex logistical hurdles can be tackled ingeniously. For anyone involved in freight, shipment, or cargo distribution, this story highlights the advantages of integrating smart technologies with lean strategies.

GetTransport.com fits naturally into this landscape, offering a reliable, cost-effective platform for varied shipping needs—including bulky, international freight, house moves, and parcel dispatching. By simplifying logistics and expanding choices globally, GetTransport.com empowers users seeking efficient and transparent transport solutions. This combination of innovation and practicality nudges the entire logistics sector closer to a future where agility and intelligence define supply chains and transportation alike.