{"id":5333,"date":"2026-05-21T10:44:12","date_gmt":"2026-05-21T10:44:12","guid":{"rendered":"https:\/\/www.icamonline.eu\/?post_type=case-study&p=5333"},"modified":"2026-06-05T13:35:26","modified_gmt":"2026-06-05T13:35:26","slug":"litokol-compatta-multi-site-logistics","status":"publish","type":"case-study","link":"https:\/\/www.icamonline.eu\/en\/case-studies\/litokol-compatta-multi-site-logistics\/","title":{"rendered":"COMPATTA for multi-site logistics management at Litokol"},"content":{"rendered":"
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\n Tripling storage capacity without expanding the facility\n <\/h2>\n \n

\n To support the expansion of the Starlike\u00ae EVO range and increase storage capacity for raw materials and finished goods, Litokol selected COMPATTA, ICAM\u2019s mobile racking system. The result: 7,000 raw material pallet locations in 2,700 sqm and 3,400 finished goods pallet locations in 1,000 sqm, all managed through FIFO logic and fully integrated with the company WMS. \n <\/p>\n <\/header>\n \n

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\n COMPATTA\n <\/p>\n <\/div>\n\n <\/article>\n \n

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\n Key result \n <\/h3>\n \n

\n Error rate reduced to just 0.04% per year thanks to ICON-WMS StockSystem integration\n <\/p>\n <\/div>\n\n <\/article>\n \n

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\n System storage capacity\n <\/h3>\n \n

\n \u2022 COMPATTA for raw materials: 20 mobile bases, 7,000 pallet locations
\r\n\u2022 COMPATTA for finished goods: 9 mobile bases, 3,400 pallet locations\n <\/p>\n <\/div>\n\n <\/article>\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n <\/section>\n

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\n Litokol: from Emilia-Romagna to over 100 countries worldwide\n <\/h2>\n \n
\n Founded in 1968 in Rubiera (Reggio Emilia), just a few kilometres from Sassuolo, the heart of the world\u2019s most renowned ceramic district, Litokol is now an international group specialising in products for the installation of ceramic floors and wall coverings, building solutions and interior decoration.
With around 600 employees, consolidated revenues exceeding \u20ac75 million and an export share of 85%, the company\u2019s products are distributed in more than 100 countries worldwide.
Its flagship products include the Starlike\u00ae EVO epoxy grout, Aquamaster EVO waterproofing solutions and StyleGrout cementitious grouts. The strong growth of these product lines made a major redesign of the plant logistics necessary.\n <\/div>\n \n <\/div>\n\n
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\n The logistical challenges\n <\/h2>\n \n
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Litokol\u2019s Rubiera operations are distributed across multiple production and logistics facilities separated by a roadway, where efficient intercompany logistics flows are essential to daily operations, not simply a matter of efficiency.<\/strong><\/p>\n

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The company faced two main challenges across separate facilities:<\/p>\n\n <\/div>\n <\/div>\n\n

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Raw materials warehouse (2,700 sqm)<\/strong><\/p>\n

\u2022 heterogeneous SKUs ranging from 30 to 1,500 kg in weight and from 50 to 200 cm in height<\/p>\n

\u2022 all pallets stacked directly on the floor, one on top of another<\/p>\n

\u2022 multiple handling operations required to access the desired batch<\/p>\n

\u2022 accatastamento che causava indurimento delle materie prime, compromettendone la qualit\u00e0<\/p>\n

\u2022 no possibility to further increase storage capacity without expanding the facility<\/p>\n

Finished goods warehouse (approximately 1,000 sqm)<\/strong><\/p>\n

\u2022 growing number of SKUs driven by the expansion of the Starlike range<\/p>\n

\u2022 finished goods temporarily stored before shipment to the picking warehouse<\/p>\n

\u2022 fully saturated space and structural columns restricting usable floor area<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/section>\n\n\n\n

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\n COMPATTA warehouse for raw materials:
\r\n7,000 pallet locations in 2,700 sqm\n <\/h2>\n \n
\n For the raw materials warehouse, Litokol installed a COMPATTA system consisting of 20 double-sided mobile bases with 5 load levels and a load capacity exceeding 430,000 kg per base. Within a footprint of 2,700 sqm, the system provides storage for approximately 7,000 pallet locations of different sizes.
All operators are equipped with handheld terminals: a simple barcode scan records every loading and unloading operation in real time within the StockSystem WMS. The mobile bases are opened remotely via radio control, creating the access aisle for direct operation with reach trucks, without requiring the operator to leave the vehicle.
\r\nAround 50\u2013100 loading operations and 30\u201340 unloading operations are performed daily.\n <\/div>\n \n <\/div>\n\n
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\n COMPATTA warehouse for finished goods:
\r\n3,400 pallet locations in 1,000 sqm\n <\/h2>\n \n
\n Satisfied with the benefits achieved through the first COMPATTA system, Litokol installed a second one in the production facility dedicated to Starlike\u00ae EVO: 9 double-sided mobile bases, each 35 metres long, for the storage of approximately 3,400 finished goods pallet locations awaiting transfer to the picking warehouse.
\r\nThe strategic division of the system into two separate sections allowed Litokol to maximise the available floor space while working around the facility\u2019s structural columns.\n <\/div>\n \n <\/div>\n\n
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\n Key results
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\n More storage capacity without relocating to a new building\n <\/p>\n <\/header>\n \n

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    \n 7,000 pallet locations in 2,700 sqm\n <\/h3>\n \n

    \n Storage capacity equivalent to 2\u20133 additional facilities within the same footprint\n <\/p>\n <\/div>\n <\/li>\n \n

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    \n 3,400 pallet locations in 1,000 sqm\n <\/h3>\n \n

    \n Starlike\u00ae EVO finished goods managed in a buffer area without saturating floor space\n <\/p>\n <\/div>\n <\/li>\n \n

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    \n 0.04% annual error rate\n <\/h3>\n \n

    \n Guided picking and StockSystem WMS traceability ensuring exceptional operational accuracy\n <\/p>\n <\/div>\n <\/li>\n \n

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    \n Automatic FIFO management\n <\/h3>\n \n

    \n Older batches are picked first, preventing obsolescence for products with a 12\u201324 month shelf life\n <\/p>\n <\/div>\n <\/li>\n \n

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    \n Raw material quality preserved\n <\/h3>\n \n

    \n No more stacked storage causing raw material compaction and deterioration\n <\/p>\n <\/div>\n <\/li>\n \n

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    \n Operational safety\n <\/h3>\n \n

    \n Photocells and remote aisle opening via radio control, without leaving the forklift\n <\/p>\n <\/div>\n <\/li>\n <\/ul>\n <\/div>\n <\/div>\n <\/div>\n <\/section>\n

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    \n Automation proved to be the strategic solution for turning complex logistics management into a competitive advantage, allowing Litokol to support production growth and international expansion without proportionally increasing warehouse footprint.\n <\/p>\n\n