Michelin Vitoria Tire Plant Automated Warehouse

Project Overview

Michelin, a 130-year-old tire manufacturing giant with global operations, operates one of its largest and highest-producing tire plants in Europe in Vitoria, Spain. The facility’s elevated manufacturing flows and planned addition of a fourth production line created a need for a refined logistic solution to manage the business growth achieved in recent years.

The project aimed to design and implement an automated logistics system tailored to Michelin’s specific requirements, particularly around the handling and storage of the company’s standard metal containers. The solution needed to integrate seamlessly with the plant’s production processes, handling container flow from production lines to delivery docks while ensuring 24/7 operational reliability.

Mecalux was selected as the system integrator to deliver a turnkey automated warehouse solution that would address the plant’s logistic challenges and support future production expansion.

Technical Solution

Automated Clad Rack Warehouse

The core of the solution is a 27-metre high automated clad rack warehouse featuring five aisles, where five single mast stacker cranes operate to handle container storage and retrieval. The warehouse is divided into two floors with distinct operational functions: inbound container processing is carried out on the lower level, while outbound operations occur on the upper level. The racking system is specially designed with cross ties that securely support the legs of Michelin’s metal containers, enabling direct storage without the need for base pallets. The warehouse has a total storage capacity of 4,600 containers, sufficient to accommodate the output of three existing production lines and a planned fourth line.

Key Features

The 27-metre high automated clad rack warehouse with five aisles and five single mast stacker cranes is a standout feature, providing vertical storage optimization and efficient container handling for the tire plant’s high production volume. The 4,600 container capacity is critical for supporting both the existing three production lines and the planned fourth line, ensuring the facility can scale with Michelin’s business growth.

The 120 containers per hour processing capacity enables the warehouse to keep up with the plant’s production and shipping demands, with the two-floor design separating inbound and outbound operations to avoid workflow bottlenecks. The pallet-free storage design, made possible by custom rack cross ties, eliminates the need for base pallets and streamlines container handling throughout the system.

The turnkey installation’s 24/7 operational capability, supported by fire safety, enclosure, and temperature control systems, ensures uninterrupted logistic support for the tire manufacturing process, while the double transfer car’s ability to hold two containers at once optimizes loading sequences and transport vehicle space utilization.

Results & Benefits

The automated logistics solution delivered by Mecalux has enabled the Michelin Vitoria tire plant to operate its warehouse smoothly on a 24/7 basis, effectively supporting the facility’s manufacturing growth and the planned addition of a fourth production line. The system efficiently handles the flow of containers from the production plant to the delivery vehicle docks, eliminating delays in the production and shipping cycle.

By using the double transfer car for load sequencing in the dispatch zone, the project has optimized space inside transport vehicles, reducing loading times and improving the efficiency of outbound logistics. The pallet-free storage design and custom WMS integration have also streamlined inventory tracking and container handling, enhancing overall operational efficiency for the tire plant.

Challenges & Solutions

Michelin faced the challenge of managing business growth driven by the planned addition of a fourth production line, alongside the need to meet the logistic demands of the facility’s elevated manufacturing flows. Mecalux addressed this by implementing a custom automated clad rack warehouse with a 4,600 container storage capacity and 120 containers per hour throughput, specifically designed to align with Michelin’s standard container dimensions and the plant’s production needs. This solution ensured the facility could scale its logistic operations to match production expansion.

Another key challenge was storing Michelin’s metal containers securely and efficiently without using base pallets, which would have added complexity and cost to the handling process. Mecalux solved this by designing the warehouse racks with special cross ties that support the container legs, enabling direct, pallet-free storage in the automated system. This design streamlined container flow from production to storage and shipping, reducing handling steps and improving operational efficiency.

System Integrator

Mecalux served as the system integrator for this project, delivering a fully customized turnkey automation solution tailored to Michelin’s specific requirements. The company was responsible for the design, supply, installation, and commissioning of the automated clad rack warehouse, material transport systems, WMS software (with integration to Michelin’s BSM system), and auxiliary systems like fire safety, enclosures, and cooling. Mecalux’s expertise in production logistics and automated warehouse solutions was critical to creating a system that operates 24/7 and supports Michelin’s manufacturing growth in Vitoria.