Industry
Doors & windows
Dirello: SILO² VLMs and COMPATTA mobile racking system for bespoke outdoor living solutions
- Doors & Windows
- COMPATTA
- SILO²
- Accessosries and components
- Long items
Different materials, one organised flow
Founded in 1983, Dirello is a manufacturer of premium bioclimatic pergolas, coverings and outdoor enclosure systems. Production is fully in-house, from engineering and aluminium machining through to assembly and testing. Each product is bespoke, with a growing mix of materials, finishes and configurations that steadily increases intralogistics complexity.
As demand grew and orders became more fragmented, Dirello chose ICAM for a logistics transformation project combining two complementary solutions: SILO² VLMs for mechanical and electrical components in the assembly area, and COMPATTA mobile racking systems with cantilever structures for aluminium profiles and palletised materials in storage.
Products
SILO²
COMPATTA cantilever
Key result
+61.5% picking efficiency
53% reduction in storage footprint for components
Key features
45.5 metres: mobile base length
ICON integration with jGalileo ERP system
Dirello: premium outdoor living, every product made to order
Based in Modugno, Italy, Dirello is a premium outdoor living manufacturer specialising in bioclimatic pergolas, canopies and outdoor enclosure systems.
Operating in the premium segment since 1983, the company follows a fully made-to-order model, with end-to-end in-house control covering design, material processing and final assembly.
A high degree of customisation and a wide range of components, including small parts, long profiles, fabric rolls and mechanical and electronic assemblies, make materials management a critical factor in ensuring quality, precision and on-time delivery performance.
Operating in the premium segment since 1983, the company follows a fully made-to-order model, with end-to-end in-house control covering design, material processing and final assembly.
A high degree of customisation and a wide range of components, including small parts, long profiles, fabric rolls and mechanical and electronic assemblies, make materials management a critical factor in ensuring quality, precision and on-time delivery performance.
The logistical challenges
A wide variety of materials in different sizes made internal logistics complex, fragmented and difficult to manage efficiently.
Aluminium bars up to 7 metres long, fabric rolls and mechanical and electronic components were stored within an unstructured system, on traditional shelving and directly on the floor. In a make-to-order production model, this setup slowed down order preparation and increased operational complexity for every single project.
The main operational challenges included:
• limited access to materials across different storage areas
• long picking times, with frequent movement between departments
• poor traceability of components and batches
• inefficient use of available space
SILO² in the assembly area: 3,000 SKUs in 23.21 m² serving multiple production lines
The SILO² VLM, featuring three storage columns and two side-by-side picking stations, is installed directly in the assembly area to serve multiple production lines simultaneously.
Within just 23.21 m², the system manages around 3,000 SKUs, including mechanical components, fasteners and electrical parts, previously distributed across more than 100 metal shelving units covering a total area of approximately 1,000 m².
The concrete result: picking time per item dropped from 65 to 25 seconds, resulting in a 61.5% efficiency gain
Within just 23.21 m², the system manages around 3,000 SKUs, including mechanical components, fasteners and electrical parts, previously distributed across more than 100 metal shelving units covering a total area of approximately 1,000 m².
The concrete result: picking time per item dropped from 65 to 25 seconds, resulting in a 61.5% efficiency gain
ICON, integrated with jGalileo ERP, provides work order picking lists and batch traceability.
ICON is integrated with Sanmarco Informatica’s jGalileo ERP system. Each operator accesses the system via a personal profile and receives work order picking lists containing between 20 and 50 items.
Trays are organised by product type to enable combined picking. For electronic items, batch integrity is maintained even within the same tray, ensuring full compliance with production lot traceability.
Average picking time per item dropped from 65 to 25 seconds, enabling a 35-item order to be completed in 15 minutes compared to 38 minutes previously.
Trays are organised by product type to enable combined picking. For electronic items, batch integrity is maintained even within the same tray, ensuring full compliance with production lot traceability.
Average picking time per item dropped from 65 to 25 seconds, enabling a 35-item order to be completed in 15 minutes compared to 38 minutes previously.
COMPATTA cantilever system for aluminium profiles: 576 bundles and 420 pallets with on-demand aisle access
The COMPATTA mobile racking system consists of five mobile bases across two separate installations, with cantilever racking spanning eight load levels. It extends over approximately 43.5 linear metres and covers a total area of 1,183 m². The system stores up to 576 bundles of aluminium profiles and 420 pallets, with direct access via a reach truck.
The mobile bases run on rails embedded in the floor, creating an operational aisle only in the required position. Operators open and close the aisle via remote control directly from the forklift, without stepping down, improving ergonomics, safety and cycle speed.
The mobile bases run on rails embedded in the floor, creating an operational aisle only in the required position. Operators open and close the aisle via remote control directly from the forklift, without stepping down, improving ergonomics, safety and cycle speed.
Key results
A more organised warehouse that genuinely supports custom manufacturing
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+61.5% efficiency in small parts picking operations
picking time per item reduced from 65 to 25 seconds, with 35-item orders completed in 15 minutes instead of 38
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53% reduction in storage space for components
footprint reduced from approximately 50 m² of shelving to 23.21 m² of SILO² in the assembly area
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50% reduction in order fulfilment time
order fulfilment time reduced from 30–45 minutes to around 15 minutes per order, with operator- and batch-guided picking lists by lot
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Full batch traceability ensured
ICON, integrated with jGalileo, tracks every movement and ensures compliance with the production sequence for electronic components
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Floor storage areas eliminated
centralised storage with full visibility of all materials across the entire production cycle
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Profiles accessible without leaving the forklift
COMPATTA Mobile Racking System with cantilever shelving and remote-controlled aisle opening reduces operational time and improves safety when handling materials up to 7 metres long
Discover how Dirello optimized its intralogistics across the entire process
ICAM understood the demands of our made to order production model and turned logistics into a competitive strength. Today we operate with more order, greater control and significantly faster throughput while maintaining the quality standards that define us.
Discover the products
SILO²: the Vertical Lift Module
From 2 to 7 storage columns, over 120 tray size configurations and a specific tray load bearing capacity of up to 1,000 kg/m²: SILO² is ICAM’s solution for high-density storage of small and medium-sized items.
Explore SILO²
COMPATTA: the Mobile Racking System
Motorized mobile bases on which any type of existing racking can be installed. COMPATTA adapts to the heaviest and bulkiest loads and operates in environments down to -30°C.
Explore COMPATTA
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