In the heart of the Veneto region—an Italian strategic hub for the fashion industry—Trascar has recently completed a major installation of its WonderBot_AMR system for a prominent client in the textile and apparel sector.
The goal was clear: to optimize the inbound handling of textile materials intended for production, using an automated system capable of delivering efficiency, flexibility, and scalability.
The project involved the creation of a dedicated warehouse for storing and handling 23,800 kilograms of yarn spools, transported on pallets. Once the materials are sorted into bins according to WMS instructions, they are picked and sent to the in-house production area, which includes over 60 looms used to manufacture high-quality fabrics.
At the core of the system is WonderBot_AMR, an autonomous mobile robot from the CTU range, equipped with a lift and a specially designed gripper capable of transporting up to eight bins at a time. The automated warehouse is built with three rows of double-deep racking—each 18 meters long, 9 meters high, and 1.27 meters deep—capable of holding up to 3,720 bins.
The robot operates at a speed of 1.5 meters per second and manages tasks at heights of up to nine meters, ensuring high-density storage and rapid handling operations.
Currently, the system runs on a single shift, but plans are already underway to expand to two shifts, with the aim of ensuring greater supply continuity to the production lines. Within the two aisles of the warehouse, WonderBot_AMR autonomously performs all handling, preparation, and bin delivery tasks to the workstations.
The Warehouse Management System (WMS) plays a crucial role in overseeing the entire cycle, intelligently orchestrating all inbound and outbound operations. The system operates on an integrated man-to-machine and machine-to-man logic, with a handling capacity of 100 totes per hour, evenly split between incoming and outgoing flows.
Each tote contains up to six yarn spools, with a total weight of 15 kilograms, making the system perfectly calibrated to the client’s specific intralogistics requirements.
Totes are routed to production machines based on the type of product to be manufactured; they can contain homogeneous batches or mixed materials, depending on the needs. This level of flexibility ensures precise and just-in-time feeding, supporting the smooth operation of the entire production workflow.
The results have been both immediate and measurable. The new Goods-to-Person system has significantly reduced the manual workload, minimized the error rate, optimized space utilization by leveraging vertical storage, and accelerated both inbound and outbound processes, enhancing overall operational efficiency. All of this comes with a higher degree of scalability compared to traditional systems such as stacker cranes or miniloads.
Notably, the entire installation was completed in just over a month—demonstrating Trascar’s strong capability to deliver cutting-edge automation solutions with speed and tangible impact on customer performance. Even in the fast-paced fashion industry—where speed, accuracy, and reliability are essential—Trascar’s WonderBot_AMR proves to be a successful and stylish choice for Goods-to-Person automation.
