Case Study of a warehouse with over 3000 orders a day

Case Study on Super Nosso

case study of shawlin islam


Minas Gerias, Contagem, Brazil


25,000 sqm /6.1 acres

Storage capacity

37,800 pallets

Pallet size

1,000 x 1,200 mm (40”x 47” approx.)

Max. pallet weight

1,300 kg

Racking height

15 meters (49 feet)

Max. racking length

113 meters (370 feet)


Challenge: Preparing 3000 orders a day

History: Founded in 1998, Super Nosso gained popularity as an online supermarket. It provides its services in a city called Belo Horizonte of Brazil.

Ever since the company was found, it tried to offer

  • innovative
  • Convenient
  • Secure system

And allow customers to make purchases 24 hours a day and on time deliveries for better user experience.

Needs of Super Nosso

According to Super Nosso, “A warehouse design is a key towards making a company more competitive.”

  • E-commerce sector is increasing rapidly; innovative processes are needed to perform better than competitors and strengthen market presence.
  • Super Nosso wants to provide the same quality people would get when they purchase from a supermarket from the comfort of their homes with proper delivery times.
  • Transport and logistics play a major role in meeting these logistics.
  • A large and efficient space is needed to get the most storage capacity out of the building.
  • A strategic, well connected location to minimize delivery times.

case study of shawlin islam

Hence, Super Nosso collaborated with Mecalux to equip 5 different stages for efficient operation and ability to serve customers repeatedly. Every day the company receives 12000 pallets and distributes 900 pallets to customers.

The decision was to have a center designed that can hold 37,800 1000 x 1200 mm pallets.

case study of shawlin islam

Logistic Challenges of online supermarkets

Generally internet sales focus on technology, leisure, culture, travel and fashion products. Similarly, food sector is also growing and people have begun to rely on supermarket websites for their weekly or monthly purchases.

The e-commerce boom has posed a hugged logistical challenge for food companies:

  • Many orders have to be prepared.
  • Some orders consist of few picking lines.
  • The products have an expiry date and goods have to be monitored constantly.
  • Food has to be kept in clean and healthy condition.
  • Cold chain of refrigerated food must be thoroughly maintained.
  • There is also demand for same day delivery.
  • Products having greatest demands are placed at the end of the aisles close to loading bays to speed up movement.

What is an online supermarket warehouse like?

  • Most of the warehouse space is occupied by 15 m (49 feet) high pallet racks.
  • Must have direct access to pallets.
  • Insertion and removal of pallets from their respective locations have to be quick.
  • Pallet racks should be adaptable to the available space to make the most out of the warehouse surface area.
  • Rack solution should be specifically designed to store diverse products of different shapes, sizes and weights.
  • Precise control of all products is necessary for precise picking and minimal error.
  • Each location assigned to a different SKU.
  • Location is assigned according to product characteristic, level of demand and packaging.

case study of shawlin islam

How to prepare 3000 orders a day?

Picking: One of the main operations in an e-commerce company warehouse. In order to pick and prepare 3000 orders a day, efficient picking is required.

Length of aisle: Due to volume of work and size of warehouse, the longest aisle measures 113 m (370 feet). Hence, careful organization of operations and workers is required.

Worker operation: Since the aisles are long, several worker operations should not meet or collide in the same aisle. This will create obstacles and slow down their work.

Control: Precise control needed to handle different products in large quantity to ensure that they are in good condition. This will minimize errors and provide flexibility in picking and storing.

Specific SKUs: Each location is assigned a single SKU (unique ID for each product). Making use of the lower rack area, once an order is completed picking; it is transferred to the consolidation area in from of the loading bays. Here, the orders are checked for errors. 

Reserves: The upper levels of the rack contain reserves for future use. This ensures that the necessary goods are always close to picker’s hands. The worker can prepare order uninterruptedly and the company can provide on time deliveries.


References: https://www.supernossoemcasa.com.br/



A breakdown of all the studies have been compiled in my Warehouse design blog

For convenience, I here are direct links to all the Research topics with proper reference.

  1. Introduction to modern "Bazaar"
  2. Literature Synthesis and Typology of warehouses
  3. Why the 19th century warehouse did not sustain? History
  4. Case Study of- A warehouse with over 3000 orders a day
  5. Site Analysis of Tejgaon Industrial Area/ Development Trend of Tejgaon Industrial Area/ Number of plots and their floor area
  6. Defining site and its surroundings according to theories of Kevin Lynch/ Site Location/ Site Area etc.
  7. Site surroundings, Location of electric poles and existing site images
  8. Project Programme
  9. Difference between traditional and modern Warehousing
  10. Fundamentals of Modern Warehousing
  11. Warehouse building types
  12. Warehouse and the Industrial Revolution
  13. What is Industry 4.0?
  14. Storage efficiency with various handling methods
  15. Industrial truck (forklift) dimensions
  16. Autonomous Vehicles in warehouse logistics
  17. Industrial Pallets, Standard pallet patterns and Standard Pallet sizes
  18. Loading Bay sizes, planning and Layout criteria
  19. Planning for fire control and Fire compartmentalization
  20. Amenity and Hygiene/ Washing and toilet facilities/ workplace design considerations
  21. Rules from BNBC Part I
  22. Rules from BNBC Part II Fire Protection
  23. List of flammable items/ Combustible dust dangers in a grocery warehouse
  24. Rat proofing/ Termite proofing in industrial buildings
  25. Industrial Shelves
  26. Field Survey
  27. Design Documents: FAR Calculation and Building code (RAJUK)
  28. Concept info graphic, Massing diagram and Volume Analysis


Read the Next Article: Site Analysis of Tejgaon Industrial Area/ Development Trend of Tejgaon Industrial Area/ Number of plots and their floor area

Read the Previous Article: Why the 19th century warehouse did not sustain? History

Link to Full portfolio: https://shawlin.net/blogs/architecture-portfolio

Older Post Newer Post

Leave a Comment

Please note, comments must be approved before they are published