NEW HIGH-ALTITUDE CONVEYOR SYSTEM BY STAMH GROUP FOR THE AUTOMATED WAREHOUSE OF SOPHARMA TRADING
Client - Sopharma Trading is a leading supplier of healthcare and pharmaceutical products and one of the most significant pharmaceutical distributors in Bulgaria and Serbia. The company operates highly automated logistics facilities and utilizes some of the most advanced warehouse systems in the Balkans, implemented in its logistics center in Sofia;
Project Location - Sofia, Bulgaria - Regional Distribution Center of Sopharma Trading. The warehouse is a highly automated pharmaceutical terminal with a complex material flow, including receiving, picking, order assembly, AS/RS replenishment, dispatching, cross-docking, and internal waste and packaging movement;
Challenge - Complex material flow and the need for a new automated segment - due to the high operational intensity, Sopharma Trading required automated transportation of picking totes from the picking and cross-docking zones to the existing conveyor line feeding the automated cranes;
Integration into an already operational automated warehouse
The warehouse uses established AS/RS systems, requiring the new Conveyor Line to be:
- 100% synchronized with the existing Automation Technologies;
- technologically compatible with the MFS/MFC logic of the distribution center;
- capable of seamless integration into the existing transportation flow;
Structural and spatial constraints
The new Conveyor had to pass through an entire System of Pallet Racking, at a height of up to 4.5 m, without interrupting ground-level operations. This required:
- a stable supporting structure;
- optimized inclines and transitions;
- a combination of horizontal, and inclined Belt and Roller Conveyor Modules;
Solution Provided by STAMH Group - STAMH Group is a leader in integrating dynamic, multifunctional Conveyor Systems (MFL – Material Flow Systems), delivering highly efficient and well-organized intralogistics transportation;
Combined Conveyor Architecture
The engineering solution includes several modules:
- Belt Conveyors – used to overcome elevation changes thanks to their high friction properties.
- Motorized Roller Conveyors – used for horizontal transport, buffering, and controlled feeding into the existing line. These modules support zero pressure accumulation technology;
Zero Pressure Accumulation (ZPA)
The system uses:
- zoning;
- optical and mechanical sensors;
- synchronization controllers;
to maintain constant and safe spacing between totes — a critical requirement in pharmaceutical logistics.
Automated Lift-Gate Module
A lift-gate conveyor segment was installed:
- closed position – totes pass without interruption;
- open position – the flow stops and accumulates via ZPA logic.
This allows convenient operator access and unobstructed movement beneath the structure.
Full Integration with the Existing AS/RS Line
The new conveyor merges directly into the crane-feeding line, providing:
- communication with the control system via PLC protocols;
- automatic synchronization of buffer zones;
- guaranteed continuous replenishment of the AS/RS storage lanes.
Achievements and results
Automation of over 140 meters of material flow
A new conveyor line was implemented, fully automating a long and critical segment of the internal logistics process;
Increased productivity and speed
- significant reduction of manual transport;
- optimized pick-path routing;
- accelerated replenishment of the automated cranes;
Uninterrupted operations on all levels
Installation at 4.5 meters enables:
- unobstructed movement of operators and equipment underneath;
- no disruption to ground-level logistics;
- safe integration through pallet rack corridors.
Guaranteed system compatibility and high energy efficiency
Thanks to zero pressure accumulation and intelligent zoning, the system maintains:
- minimal energy consumption;
- low mechanical wear;
- exceptionally smooth material flow;
Improved safety and standardization
- standardized movement of totes;
- reduced human error;
- enhanced ergonomics and minimized operational risks;
