Projects Flagship Case Study

High-Density Vertical Handling & Storage System

An engineered solution that tripled storage capacity, automated handling, and optimized production flow within a highly constrained industrial site.

Load: 1-Ton Containers Scope: Specialized Solution Sector: Food Processing

The Challenge

The client operated a food processing factory utilizing 1-ton industrial containers for pickled products. The operation was choking due to severe space limitations and manual inefficiencies.

  • Extremely limited storage footprint.
  • Multiple production lines on different floors (1st to 3rd).
  • Manual handling was slow, unsafe, and labor-intensive.
  • Complex requirement to wash, refill, and redistribute containers.
"The challenge was not storage alone — it was storage + hygiene + vertical logistics + operational flexibility in a confined footprint."

Project Objectives

To engineer a system that could multiply capacity and streamline operations without acquiring new land.

Multiply Capacity

Increase storage without expanding the physical footprint.

Automate Handling

Eliminate manual forklift operations for safety.

Vertical Integration

Seamlessly connect ground storage to upper production floors.

Hygiene Control

Automate washing and ensure strict sanitation standards.

Turnkey Execution

Scope & Responsibility

Site Engineering

Maximizing a 100m x 5m side zone.

  • Layout planning
  • High-density logic
  • Drainage design

Civil & Infra

Heavy-duty foundation for wet operation.

  • Reinforced flooring
  • Integrated drainage
  • Load-bearing surface

Material Handling

Custom automated handling systems.

  • Overhead crane system
  • Overhead forklift
  • Truck unloading

Washing Systems

Integrated hygiene station.

  • Automated spray
  • Water replacement
  • Waste handling

Vertical Handling

Connection to upper floors.

  • Custom industrial elevator
  • 1-ton capacity lift
  • Floor integration

Automation

Smart control and safety.

  • Wireless controls
  • Load weighing
  • Safety interlocks

Engineering Challenges Solved

Challenge 1

Severe Space Constraints

Only a narrow strip of land was available for storage expansion.

Our Solution:

A linear, high-density storage system was engineered, utilizing vertical stacking and overhead handling to increase capacity while using only 25% of the previous area.

Challenge 2

Safe Handling of 1-Ton Loads

Manual or forklift handling of liquid-filled 1-ton containers posed severe safety risks.

Our Solution:

We designed a custom overhead crane with a specialized forklift attachment, eliminating ground traffic and removing the need for manual rigging.

Challenge 3

Multi-Floor Logistics

Containers needed to be delivered to production lines on the 1st, 2nd, and 3rd floors efficiently.

Our Solution:

A custom-built industrial elevator was manufactured locally and integrated into the workflow, specifically designed for container dimensions and loads.

System Architecture

1. Truck Arrival

Material Reception

2. Overhead Crane Unloading

Automated Intake

3. High-Density Storage

150 Tons Capacity

4. Washing & Drainage

Integrated Hygiene

5. Selective Retrieval

On-Demand Access

6. Industrial Elevator

Vertical Transport

7. Production Lines

Floors 1-3

Fully Integrated Horizontal + Vertical Logistics System

Impact & ROI

Operational

  • Storage capacity tripled (150T)
  • Selective individual access
  • Seamless floor integration

Space Optimization

  • Used only 1/4 of previous area
  • Linear high-density layout
  • Improved overall site flow

Safety & Hygiene

  • Elimination of manual lifting
  • Controlled washing system
  • Reduced internal traffic

Total Project Value: approx. 2 million EGP — ROI achieved through space savings and labor reduction.

Why This Is A Flagship Project

This project proves our ability to engineer non-standard handling systems. It demonstrates the successful combination of civil, mechanical, and automation disciplines to solve space-driven problems, manufacturing custom vertical systems, and delivering hygienic solutions under real constraints.

Unlock Hidden Capacity

If your facility suffers from space limitations, manual handling risks, or inefficient internal logistics, this project demonstrates how engineered systems can unlock hidden capacity.

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