{"id":4866,"date":"2026-05-19T10:26:58","date_gmt":"2026-05-19T10:26:58","guid":{"rendered":"https:\/\/www.icamonline.eu\/?post_type=case-study&p=4866"},"modified":"2026-06-19T09:57:17","modified_gmt":"2026-06-19T09:57:17","slug":"gls-silo2-automated-package-management","status":"publish","type":"case-study","link":"https:\/\/www.icamonline.eu\/en\/case-studies\/gls-silo2-automated-package-management\/","title":{"rendered":"GLS: SILO\u00b2 automates exception parcel management, reducing inventory time from 2 hours to 2 minutes"},"content":{"rendered":"
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\n When every missed delivery becomes a new delivery mission\n <\/h2>\n \n

\n In last-mile logistics, delivery exception parcels generate a continuous operational flow. Receiving, identification, storage and redelivery activities take place every day, handling volumes that continue to grow year after year.
When managed manually, what should be a routine process can quickly become a bottleneck, slowing operations, consuming valuable space and ultimately affecting the service experience delivered to the end customer. \n <\/p>\n <\/header>\n \n

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\n Industry\n <\/h3>\n \n

\n Distribution and Logistics\n <\/p>\n <\/div>\n\n <\/article>\n \n

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\n \n\n<\/svg> <\/div>\n \n
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\n Product\n <\/h3>\n \n

\n SILO\u00b2\n <\/p>\n <\/div>\n\n <\/article>\n \n

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\n Key results \n <\/h3>\n \n

\n \u2022 98% reduction in inventory time, from 2 hours to 2 minutes
\r\n\u2022 78% faster redelivery list processing, from 90 to 20 minutes\n <\/p>\n <\/div>\n\n <\/article>\n \n

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\n \n\n\n<\/g>\n\n\n\n<\/clipPath>\n<\/defs>\n<\/svg> <\/div>\n \n
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\n Key feature\n <\/h3>\n \n

\n Side-by-side picking\/refilling stations, IRIDE and dual loading modes\n <\/p>\n <\/div>\n\n <\/article>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/section>\n

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\n GLS<\/span>: a last-mile logistics network spanning 40 countries\n <\/h2>\n \n
\n GLS (General Logistics Systems), part of the Royal Mail Group, operates in 41 countries and serves more than 120,000 customers through a network of over 147 depots across Italy. The Cosenza branch, active for more than 25 years, employs around 70 people, including warehouse operators, drivers and office staff, operates a fleet of more than 40 vehicles and serves over 2,000 customers across the province every day.
As e-commerce volumes have continued to grow, managing delivery exception parcels, shipments that are not delivered on the first attempt and remain in storage awaiting redelivery or customer collection, has become a critical factor in maintaining both service quality and operational efficiency. \n <\/div>\n \n <\/div>\n\n
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\n \"GLS:\n <\/div>\n <\/figure>\n <\/div>\n <\/div>\n <\/section>\n
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\n The logistical challenges\n <\/h2>\n \n
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Annual parcel volumes at the Cosenza branch were growing by around 20%, making manual handling of delivery exception parcels increasingly unsustainable.<\/strong><\/p>\n

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The management of exception parcels had become a major operational bottleneck, affecting processing times, operating costs and, ultimately, the quality of service experienced by the end customer.<\/p>\n\n <\/div>\n <\/div>\n\n

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The main operational challenges included:<\/p>\n

\u2022 around 1,200 parcels per day stored on the floor across approximately 200 m\u00b2, exposed to dust and dirt<\/p>\n

\u2022 manual parcel searches for redelivery list preparation, requiring around 2.5 hours per day<\/p>\n

\u2022 daily inventory checks based on manual scanning of every parcel, taking more than 2 hours<\/p>\n

\u2022 frequent retrieval errors affecting delivery times and customer satisfaction<\/p>\n

\u2022 during peak seasons, storage areas reached full capacity, requiring additional temporary staff<\/p>\n

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\n Multi-column SILO\u00b2 VLM for high-density storage of exception parcels\n <\/h2>\n \n
\n The SILO\u00b2 VLM stands nearly 8 metres high and features three storage columns within a footprint of just 23 m\u00b2.
\r\nThe trays, equipped with side panels and dividers, can handle packages weighing from 100 g to 35 kg and up to 60 cm in height. The trays, equipped with side panels and dividers, can handle packages weighing from 100 g to 35 kg and up to 60 cm in height.
\r\nAutomatic space allocation based on parcel dimensions optimises tray occupancy and maximises the use of available storage capacity.
Each tray can be reconfigured over time to accommodate future operational requirements and changing storage needs. \n <\/div>\n \n <\/div>\n\n
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\n \"SILO\u00b2\n <\/div>\n <\/figure>\n <\/div>\n <\/div>\n <\/section>\n
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\n 3D scanning, ICON and IRIDE: full parcel traceability from receipt to retrieval\n <\/h2>\n \n
\n Upon arrival, each parcel is processed by a 3D scanner that captures its weight and dimensions and transfers the data to the GLS ERP system, integrated with ICON.
\r\nL’operatore sceglie tra due modalit\u00e0 di carico: selettiva, con un collo alla volta e vassoio assegnato automaticamente da ICON in base all’ingombro, o massiva, con pi\u00f9 colli depositati in sequenza su vassoi vuoti disponibili.
\r\nIn both cases, barcode scanning creates a unique link between the shipment number and its storage location within the VLM, ensuring full real-time traceability and retrieval accuracy.
The two side-by-side picking\/refilling stations operate in parallel, while IRIDE guides each retrieval through visual instructions displayed directly in front of the operator. Operations can be confirmed or adjusted via the control panel, without the need to access the control console PC. \n <\/div>\n \n <\/div>\n\n
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\n \"3D\n <\/div>\n <\/figure>\n <\/div>\n <\/div>\n <\/section>\n
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\n Key results
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\n More speed, greater control and less waste for both operators and end customers\n <\/p>\n <\/header>\n \n

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    \n Inventory time: \u201398%\n <\/h3>\n \n

    \n Inventory from 2 hours to 2 minutes\n <\/p>\n <\/div>\n <\/li>\n \n

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    \n Redelivery lists: \u201378%\n <\/h3>\n \n

    \n Redelivery lists in 20 minutes\n <\/p>\n <\/div>\n <\/li>\n \n

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    \n \u201340% picking errors\n <\/h3>\n \n

    \n IRIDE guides every operation\n <\/p>\n <\/div>\n <\/li>\n \n

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    \n 1,200 parcels\/day in 23 m\u00b2\n <\/h3>\n \n

    \n Compared with the 200 m\u00b2 of floor space previously required\n <\/p>\n <\/div>\n <\/li>\n \n

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    \n Full traceability\n <\/h3>\n \n

    \n Every parcel linked to its position, locatable in seconds\n <\/p>\n <\/div>\n <\/li>\n \n

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    \n Shorter counter waiting times\n <\/h3>\n \n

    \n The parcel is available at the picking\/refilling station within seconds of entering the shipment number into the ERP system.\n <\/p>\n <\/div>\n <\/li>\n \n

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    \n Seasonal peaks managed\n <\/h3>\n \n

    \n High parcel volumes handled without additional staff, even during the Christmas peak season\n <\/p>\n <\/div>\n <\/li>\n \n

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    \n Improved customer satisfaction\n <\/h3>\n \n

    \n More reliable deliveries improve service quality\n <\/p>\n <\/div>\n <\/li>\n <\/ul>\n <\/div>\n <\/div>\n <\/div>\n <\/section>\n

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    \n Thanks to the installation of a vertical storage system, GLS have been able to benefit from a number of advantages. The first undoubtedly relates to savings in terms of human resources and therefore the overall cost of labour for the company. In addition, there has also been a reduction in the queues that formed as customers waited to collect their packages. Another advantage has been the possibility to automatically manage the storage system. Lastly, we have been able to increase the level of security for the goods we store. Today these packages are safely stored inside the SILO\u00b2, where they are protected from any unauthorized access, but above all from the dust and dirt that are commonly found in a warehouse environment.\n <\/p>\n\n