The Morocco Tire Industry Rack-Supported Warehouse Project is a customized automated clad rack warehouse solution designed for a global tire manufacturer to optimize finished tire storage, improve warehouse space utilization, and enhance logistics efficiency.
Considering the characteristics of tire products, including large volume, heavy loads, high storage requirements, and continuous outbound demand, Zhuku designed an integrated warehouse solution combining rack-supported structure (Silo Clad Warehouse), ASRS technology, stacker crane automation, pallet shuttle system, and intelligent warehouse management systems.
The project enables high-density automated storage while providing stable and efficient material handling support for tire production and distribution operations.
Project Information
| Item | Details |
| Industry | Tire Manufacturing |
| Application | Finished Tire Storage |
| Warehouse Type | Rack-Supported Automated Warehouse |
| Warehouse Size | 166 m × 102 m × 40.5 m |
| Rack Height | 40.5 m |
| Rack Layer | 18 |
| Storage Capacity | 71,280 Pallet Positions |
| Solution Type | Automated Clad Rack Warehouse |
| Main Equipment | Stacker Crane + Shuttle Lift + Truss Robot |
| Location | Morocco |
Project Challenges
Large-Scale Finished Tire Storage Requirements
The customer required a warehouse capable of storing a large quantity of finished tires while maintaining efficient inventory turnover.
Main challenges included:
- Limited land availability
- High storage volume requirements
- Heavy pallet loads
- Frequent inbound and outbound operations
- Need for accurate inventory management
- Requirement for automated warehouse operation
Traditional storage methods could not provide sufficient capacity and operational efficiency.
Solution Design: Rack-Supported Automated Warehouse
Zhuku designed a complete rack-supported warehouse where the storage rack structure also serves as the supporting framework of the building.
The solution integrates:
- High-strength rack structure
- Automated storage equipment
- Intelligent control system
- Warehouse management software
This design maximizes vertical space utilization and reduces construction requirements, and it's very suitable for Automotive Warehouse Automation.
Main Equipment Configuration
High-Bay Rack-Supported Structure
The warehouse adopts a high-bay rack-supported structure integrating the storage rack system and building structure, providing a stable foundation for automated pallet storage.
Features:
- 40.5 m high storage structure
- Heavy-duty load capacity
- Optimized pallet positioning
- Stable long-term operation
Stacker Crane AS/RS System
The stacker crane system is the core automated storage equipment, responsible for precise pallet storage and retrieval operations inside the high-bay warehouse.
Functions:
- Automatic pallet storage
- Automatic retrieval
- High-precision positioning
- Efficient vertical and horizontal movement inside storage aisles
Pallet Shuttle Transfer System
The pallet shuttle system is used as an automated pallet transfer solution between the floor buffer area and the stacker crane station.
After pallets are temporarily stored on the ground buffer area, pallet shuttles automatically transport pallets to the stacker crane transfer position. The stacker crane then completes the final storage operation inside the rack-supported warehouse.
Benefits:
- Automated pallet transfer from buffer area to AS/RS
- Reduced forklift dependency
- Improved inbound handling efficiency
- Smooth connection between manual and automated processes
- Increased overall warehouse throughput
Truss Robot System
The integrated truss robot supports automated material transfer and improves warehouse flow efficiency.
Advantages:
- Automated transportation
- Reduced manual handling
- Improved operational consistency
Project Highlights
71,280 Pallet Positions
The high-density rack-supported structure provides large-scale storage capacity within a limited footprint.
40.5 Meter High Automated Warehouse
The high-bay design maximizes vertical space utilization and improves land efficiency.
Integrated Automation Solution
Multiple automation technologies work together to create an efficient warehouse operation.
Improved Storage Efficiency
Automated storage and retrieval reduce manual handling and improve inventory accuracy.
Project Benefits
Maximized Warehouse Capacity: The rack-supported structure significantly increases storage density compared with traditional warehouses.
Improved Operational Efficiency: Automation enables faster pallet movement and reduces dependency on manual operations.
Better Inventory Management: The intelligent warehouse system provides real-time inventory visibility and accurate storage management.
Reduced Long-Term Operating Costs: Optimized warehouse layout and automation help reduce labor requirements and improve operational stability.
Why Choose Zhuku?
Zhuku provides complete intelligent warehouse system integration solutions, covering:
- Warehouse planning
- Rack-supported warehouse design
- Structural engineering
- Automation equipment integration
- WMS/WCS software
- Installation and commissioning
- Technical support
With extensive experience in automated warehouses, shuttle systems, and AS/RS projects, Zhuku helps global customers build efficient, scalable, and intelligent logistics facilities.
