Malfini
Automated carton storage supporting apparel distribution
KVADOS GROUP
Malfini
Malfini is a supplier of promotional and customized clothing and workwear serving 37 European countries. Its logistics operation in Ostrava distributes products across its Malfini, Malfini Premium, Piccolio, and Rimeck brands.
As the business grew, Malfini needed its reserve carton storage to keep pace within its existing operation. Working with Hai Robotics and Kvados, the company introduced automated carton storage and retrieval to handle inbound peaks and make better use of the warehouse’s vertical space.
Challenges
Malfini receives clothing and apparel items in cartons. Before products could enter their previous automation setup, they had to be unpacked into totes. Reserve cartons were stored in conventional racking and handled manually using very narrow aisle equipment, creating a need for greater storage density and reserve-storage performance. The solution also needed to handle varying carton sizes and loads of up to 30 kg at heights approaching 12 meters. Malfini required an automation system that could:
- Increase reserve-storage density within the existing warehouse.
- Process peak inbound shipments quickly and reduce container time on site.
- Supply cartons efficiently to the preparation area for the next stage of order fulfillment.
- Handle cartons reliably at height and connect with existing warehouse systems.
Our Solutions
Hai Robotics and Kvados implemented a HaiPick carton storage system with three A42TD robots. The design combines double-deep and single-deep racking, overhead storage, and outbound flow racks, providing approximately 30,000 locations within an automation area of around 1,150 m². Robotic handling up to 12 meters makes use of the building’s approximately 12.5-meter clear height.
Before implementation, a one-aisle proof of concept tested carton handling at height and verified the required throughput of approximately 75 cartons per hour. This gave Malfini a basis for proceeding with the wider deployment.
Two inbound and two outbound conveyor docking points connect the robots with carton flows. The receiving process includes dimension and weight checks, with handling or repacking where needed. The retrieved cartons move to a preparation area, where products are transferred into totes. Another 288 flow-rack locations allow workers to pick selected cartons that do not need to be exchanged to totes.
Solution continued
To handle inbound peaks, the system was designed to process a container of cartons in approximately one hour. During these periods, robots place cartons in the nearest available rack columns to prioritize receiving speed. After the peak, cartons can be reorganized according to ABC classifications or other storage rules.
Kvados integrated Malfini's existing WMS with Hai Robotics through a white-box architecture. Kvados’ warehouse execution system manages warehouse logic, while HAIQ-ESS coordinates robot allocation, routing, traffic, and charging. The integration scope also covered coordination with the conveyor supplier.
Results
Proof of concept validated carton handling
The initial test verified handling at the required storage height and throughput of approximately 75 cartons per hour. These findings supported the move from a single-aisle trial to the implemented system.
Automated reserve storage connected to existing operations
The implemented system automates carton storage and retrieval alongside Malfini's existing operation. It covers one part of the approximately 10,000 m² warehouse, while much of the remaining space continues to operate with very narrow aisle equipment.
Capacity for future warehouse phases
The first phase establishes approximately 30,000 automated storage locations. Malfini has further phases planned within the same warehouse and is considering a similar architecture at another Czech site.
Contact Hai Robotics to explore how automated storage can support inbound operations and make better use of your warehouse space.