Efficiently in motion

Automated Two-Level Pallet Conveyor Technology

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Pioneering PPC Technology for Sustainable Beverage Logistics

An international beverage manufacturer and renowned general contractor are investing in a new, highly automated logistics center at their site in Spain. Located directly adjacent to the country’s largest and most productive beverage manufacturing plant, this cutting-edge warehouse concept will connect production, high-bay storage, and shipping seamlessly by 2027. As part of this major project, ROFA INDUSRIAL AUTOMATION GROUP has implemented two innovative electric pallet conveyor systems (PPC). These systems will handle the automated transport of pallets loaded with beverage crates between the production lines and shipping zones.

A new dimension in conveyor technology

The client's requirements were demanding: high transport volumes, various pallet types (EURO, INDU, EU), and payloads up to 2,400 kg per double vehicle had to be managed with maximum reliability. At the same time, the systems needed to be integrated into the architecture of an existing production facility, featuring multi-level construction, confined spaces, and stringent hygiene standards.

Double-level percision and power

ROFA developed two PPC systems that together form the backbone of the new pallet transport operation. Both systems connect production lines, warehouse zones, and shipping stations in a continuous material flow. Particularly noteworthy is the newly developed double vehicle on the 0 m level (with a conveyor height of 700 mm and a track gauge of 1,000 mm), which represents a technical highlight of the project. It combines an exceptionally low conveyor edge with an integrated swivel-tilt unit to ensure precise pallet handover onto gravity roller conveyors. With five drives—a travel motor, two motors for roller conveyance, and two for the tilt function—this vehicle sets new standards in PPC technology. The comprehensive installation, enhanced by express switches, diagnostic stations, and specialized vacuum vehicles, stands for an innovative, high-performance, and maintenance-friendly conveyor system. On the 6-meter level (conveyor height 1,000 mm, track gauge 600 mm), a compact double vehicle system ensures transport between the high-bay warehouse and production. Both systems were developed with a focus on energy efficiency, ease of service, and digital connectivity.

Joint path to go-live

From the initial conceptual phase in 2024 through the scheduled commissioning in 2026, ROFA worked closely with the client and system partner. After the development and design phase, prototype vehicles were assembled and subjected to comprehensive tests on the ROFA test loop. In parallel, software integration, safety approvals, and digital interfaces to warehouse control systems were prepared. The installations in Spain occurred in phases to avoid disrupting ongoing production. The 6-meter system was installed first, followed by the more complex 0-meter system with its new tilting function. This innovative swivel-tilt technology increases throughput, reduces manual interventions, and guarantees ergonomic, low-maintenance handling. With this project, ROFA demonstrates its expertise in developing complex, customized conveyor systems and bolsters the international beverage manufacturer’s position as a pioneer in sustainable industrial automation in Europe.

Test loop for quality assurance

A test loop was set up at ROFA in Kolbermoor for quality assurance, where the vehicles were pre-assembled, wired, and commissioned - an essential step to seamlessly implement the complex movement and transfer processes on-site.