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Case study bracell

THE COMPANY

Bracell is a global leader in the production of soluble and specialty cellulose, with operations in Brazil in the states of Bahia and São Paulo. 

The company stands out as one of the world’s largest producers of raw materials used in the manufacture of viscose, rayon, pharmaceuticals, and food products.
Recently, the company consolidated its position with the completion of “Project Star,” an imposing expansion in the state of São Paulo that gave rise to one of the largest and most modern cellulose factories on the planet. In addition to industrial cellulose, Bracell has recently expanded into the consumer tissue and sanitary paper products market.

CUSTOMER NEED

Due to the expansion of its operation, with a projected capacity of 286,000 tons per year, a robust solution for finished product storage was required. This system must support high demand, operational complexity, and integration with logistics and IT processes while maintaining rigorous safety and efficiency standards. Key challenges include physical space limitations, the need for high-density storage, integration with conversion lines and ERP systems, and compliance with technical standards and fire safety requirements. The project also demands robust electrical and IT infrastructure. In summary, this project represents a strategic step for Bracell, consolidating its ability to serve the market with operational excellence, advanced technology, and global quality and safety standards.

THE CASSIOLI SOLUTION

Cassioli presented a comprehensive solution featuring a self-supporting warehouse capable of storing approximately 24,000 pallet positions, with high-intensity throughput: inputs of up to 140 pallets per hour and outputs reaching 200 pallets per hour. Operations will be continuous, 24/7 over three shifts, with about 50-100 different SKUs. Furthermore, 60% of movements involve pallet picking, which increases the need for intelligent automation and integration with management systems.
The solution offers a complete system: self-supporting metal structure, stacker cranes, conveyor belts, management software, electrical and automation systems, as well as integration with existing conveyors. It is also essential to ensure secure interfaces with SAP via webservice, integration monitoring, and compliance with cybersecurity requirements.

ADVANTAGES

SPACE OPTIMIZATION AND LOGISTICS EFFICIENCY

REDUCTION OF SAFETY AND OPERATIONAL COSTS

REDUCTION OF DAMAGE TO STORED MATERIALS

CONTINUOUS PERFORMANCE MONITORING AND MATERIAL TRACEABILITY

MAXIMUM EXPLOITATION OF AVAILABLE SPACE

MAXIMUM ORGANIZATION OF THE WORK ENVIRONMENT

INVENTORY CONTROL WITH CASSIOLI WMS AND TOTAL INTEGRATION WITH THE CLIENT’S ERP

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