HAVI Lisbon Multi-Temperature Logistics Center

Project Overview

HAVI, a global leader in logistics and supply chain management services with around 10,000 employees worldwide, needed to replace its existing distribution centre in Portugal that lacked sufficient capacity to meet the growth needs of its food service clientele. The company invested in a modern, high-tech logistics centre in Lisbon, Portugal, designed to integrate all necessary operations and deliver greater efficiency in managing client processes.

The primary goal of the project was to create a facility that could accommodate all of HAVI’s clients’ service needs and their full product range, which includes ambient, refrigerated and frozen food items. The centre needed to maintain strict cold chain integrity while also improving operator ergonomics by automating arduous manual tasks, particularly in sub-zero temperature zones.

Mecalux was selected as the partner for this project due to the long-standing collaboration between the two companies and Mecalux’s expertise in designing custom storage solutions for temperature-controlled warehouses. Mecalux delivered a comprehensive solution including automated storage systems, pallet racking, Pallet Shuttle technology and the Easy WMS warehouse management system integrated with HAVI’s existing WMS.

Technical Solution

Multi-Temperature Warehouse Zones

The HAVI logistics centre is divided into three distinct temperature-controlled zones: a freezer warehouse operating at -24°C, a refrigerated warehouse at 4-8°C, and an ambient-temperature warehouse. The freezer zone stores hamburgers, potatoes, chicken products and bread; the refrigerated zone houses vegetables and pastries; and the ambient zone stores beverages and sauces. Each zone is equipped with tailored storage solutions, and 24/7 temperature sensors monitor conditions across the facility, sending real-time alerts for any deviations from established temperature limits to ensure cold chain integrity.

Key Features

The three temperature-controlled zones (-24°C freezer, 4-8°C refrigerated, ambient) enable HAVI to store and manage a full range of food products, meeting all client service needs for different temperature requirements. The automated Pallet Shuttle system in the freezer warehouse offers a large storage capacity of 2,243 pallets and automates the handling of frozen goods, reducing manual labour in harsh sub-zero conditions.

The combination of 1 automated and 2 manual pick stations in the freezer warehouse allows for the simultaneous preparation of up to 12 orders, significantly increasing order fulfillment throughput. The anthropomorphic robotic arm in the automated picking zone further enhances efficiency by filling 4 orders at a time with precise stackability control.

The 24/7 temperature sensors throughout the facility provide real-time monitoring and alerts for temperature deviations, guaranteeing the integrity of the cold chain for frozen and refrigerated products—an essential requirement for food logistics operations. The integration of Easy WMS with HAVI’s own warehouse management system ensures end-to-end stock control, product traceability and optimised order sequencing across all warehouse zones.

Results & Benefits

The HAVI logistics centre in Lisbon successfully supplies over 150 restaurants in Portugal daily, meeting the growing demand of HAVI’s food service clients with its expanded capacity and efficient multi-temperature operations. The implementation of automated storage and picking systems has drastically improved operator ergonomics, particularly in the freezer warehouse where robots and Pallet Shuttles handle arduous tasks in sub-zero temperatures, reducing physical workload and contributing to low employee turnover.

The facility maintains unbroken cold chain integrity across all storage and dispatch processes, thanks to 24/7 temperature sensors and temperature-controlled dispatch zones. This ensures compliance with food safety standards and guarantees the quality of frozen and refrigerated products delivered to clients. The integration of Easy WMS with HAVI’s WMS has enabled real-time product traceability, improved stock control and optimised storage/retrieval times, boosting overall operational efficiency and ensuring compliance with legal traceability requirements for food products.

The automated and semi-automated Pallet Shuttle systems, along with the AS/RS in the ambient zone, have maximised storage density and space utilisation across the facility. The ability to prepare up to 12 orders simultaneously in the freezer warehouse has also increased order fulfillment speed, allowing HAVI to meet tight delivery deadlines for its restaurant clients.

Challenges & Solutions

HAVI faced the challenge of insufficient capacity at its old distribution centre, which could no longer support the growth needs of its clientele. Mecalux addressed this by designing and building a new, larger logistics centre in Lisbon with three temperature-controlled zones and a range of automated storage systems, including Pallet Shuttles and AS/RS, to scale storage and fulfillment capacity and integrate all necessary operations in one facility.

Maintaining the cold chain for frozen and refrigerated food products throughout storage, picking and dispatch was a critical challenge for HAVI. Mecalux implemented 24/7 temperature sensors with real-time alert functionality across the facility, as well as temperature-controlled dispatch zones and automated systems that minimise human intervention in sub-zero environments. These measures ensure that the cold chain remains unbroken, complying with food safety standards and preserving product quality.

Improving operator ergonomics was another key challenge, as HAVI’s logistics operations involved manual, physically demanding tasks—especially in sub-zero freezer zones. Mecalux deployed automated Pallet Shuttle systems, an anthropomorphic robotic picking arm and an AS/RS to automate these arduous tasks, reducing the physical workload on operators and creating a safer, more sustainable working environment. This has also helped HAVI maintain low employee turnover by supporting its staff with technology that eases manual labour.

System Integrator

Mecalux served as the sole system integrator for HAVI’s Lisbon logistics centre project, partnering with HAVI from the project’s conception through to the facility’s operation and ongoing maintenance. Mecalux designed and supplied all storage systems, including two automated warehouses, pallet racks, drive-in racks and Pallet Shuttle systems (both automated and semi-automated), as well as deploying the Easy WMS warehouse management system and integrating it with HAVI’s existing WMS.

The long-standing collaboration between Mecalux and HAVI—including previous projects like HAVI’s first automated warehouse in Russia—enabled Mecalux to deliver a custom solution tailored to HAVI’s specific operations in Portugal, including its client requirements and volume handling needs. Mecalux also provides ongoing after-sales service and maintenance support for the facility, ensuring the smooth day-to-day operation of the automated systems.