Lyreco optimises its logistics flows thanks to the Exotec order-picking buffer

At its long-established distribution centre in Villaines-la-Juhel (Mayenne), Lyreco has implemented the Exotec sequencing buffer to replace an obsolete sorting system. The result: the time taken to prepare the 200–300 pallets per day has been reduced from 14 to 7 hours (in a single shift), doubling productivity.

Who is Lyreco?

Lyreco France is the leading distributor in France of products and services for the workplace: from office supplies to personal protective equipment (PPE), from IT equipment to furniture, right through to hygiene products, catering supplies and packaging for shipments.

Established for over 55 years in Villaines-la-Juhel, in the Mayenne region, the Lyreco distribution centre is a long-standing facility at the heart of the Group’s supply chain. Its role is to receive goods, store them and prepare orders for next-morning delivery to the last-mile distribution centres, which are responsible for delivering to the company’s retail outlets.

This major undertaking requires a consistent operational pace: 5,500 orders are processed every day, totalling 35,000 order lines and nearly 25,000 parcels handled.
Faced with the natural obsolescence of its existing equipment and the growing need to improve operational performance, Lyreco chose to partner with Exotec to replace its outdated sorting system with a modern solution capable of simultaneously meeting the requirements for productivity, ergonomics and service quality.

The Challenge

An outdated sorting system

The old system was no longer able to meet the site’s growing operational requirements. Palletising the 200–300 pallets dispatched daily to last-mile distribution centres required two shifts, totalling 14 hours of operation.

Increased risk of musculoskeletal disorders (MSDs)

Under the previous set-up, operators had to manually handle packages weighing several kilograms. Lifting, carrying and positioning these loads, both on the ground and at height on pallets, throughout the working day led to an increased risk of musculoskeletal disorders (MSDs) and greater fatigue for the operators.

Less stable pallets: a source of risk

In the absence of a sequencing algorithm, the order in which the packages were dispatched was also uncontrolled. The heaviest products might end up at the top of the pallet, compromising its stability and increasing the risk during handling.

The solution

The solution comprises 105 robots, 22,000 storage locations, 6 Exchangers and 5 palletising bays, achieving a handling capacity of 3,200 parcels per hour.

Robots	Storage locations	Exchangers	Palletising bays	Packages per hour	Pallets per day
105	22,000	6	5	3200	200 to 300

1.The Exotec sequencing buffer

Exotec has implemented a pure buffer system at the Villaines-la-Juhel site: parcels enter the system throughout the day’s production cycle, are stored in one of the 22,000 available storage locations and are then released at the end of the day to feed the palletising bays, already in the correct order.

“The main difference between the old sorting system and the new Exotec solution lies in ergonomics.”

— Cédric Renaud, Distribution Centre Manager, Lyreco Villaines-la-Juhel

2. A palletising algorithm developed by Exotec

The buffer is sized to accommodate the site’s entire daily output. The greater the number of pallets available when palletising begins, the greater the algorithm’s ability to build optimised pallets.

The algorithm, developed entirely in-house by Exotec’s software teams, determines the order in which parcels are dispatched to ensure that pallets are structured correctly: the heaviest products are placed at the base, those of medium weight in the centre, and the lightest and most fragile parcels at the top.

“The buffer-only solution would have been of no use without the intelligence required to release the parcels in the correct order. This is precisely the result we have achieved thanks to the work of our software teams.”

— Louis-Nicolas Leurent, Systems Engineer, Exotec

3. More ergonomic workstations

Designed in collaboration with Elten, the five palletising bays have been engineered to eliminate the most physically demanding movements for operators. The package is delivered directly to the workstation via a conveyor and a spiral roller conveyor. The operator simply has to slide it onto the pallet, without having to lift or carry it.

During the loading process, the pallet itself gradually descends into the bay, allowing the operator to work at a comfortable and ergonomic height at all times.

Once the pallet is complete, the operator moves it outside: the safety gate closes automatically, the pallet is wrapped in stretch film, labelled with its destination, weight and a barcode for traceability, and then moved directly to the loading bay.

Key benefits

1. Productivity doubled

Whereas the previous system required 14 hours and two shifts to palletise 200–300 pallets per day, the Exotec solution enables the same volume to be handled in just 7 hours, delivering a 100 per cent increase in productivity. This improvement significantly reduces the organisational workload at the site and supports the ongoing skills development programme.

2. 8,000 m² of reclaimed space

The Exotec sequencing buffer takes up three times less space than the previous system. This greater compactness has enabled Lyreco to reclaim 8,000 m² within the existing building, which is now available for new activities or to support the site’s future growth.

3. Ergonomics reimagined

Operators no longer have to move parcels manually. They always work at the same height, simply sliding the parcels along the work surface, without having to perform repetitive twisting or lifting movements that used to cause fatigue and increase the risk of musculoskeletal disorders (MSDs).

A tangible transformation of day-to-day work, accompanied by a significant reduction in movement within the warehouse and an improvement in the team’s inclusivity.

4. Higher-quality and safer pallets

Thanks to the sequencing algorithm, each pallet is built according to a precise system: from the heaviest package to the lightest, from the bottom to the top.

The result is more stable pallets during transport and a reduction in risks during unloading operations at the loading bays of last-mile distribution centres.

“A partnership is a relationship based on trust between two companies that need to work together to achieve the project’s objective. That is exactly what Lyreco and Exotec are doing: together.”

— Cédric Renaud, Distribution Centre Manager, Lyreco Villaines-la-Juhel

Conclusion

Lyreco’s experience demonstrates that logistics automation is not just about increasing productivity, but also about improving workplace ergonomics, the quality of palletising and the operational flexibility of the entire distribution centre.

Thanks to the Skypod® sequencing buffer and the algorithms developed by Exotec, the Villaines-la-Juhel site has reduced pallet preparation times by 50 per cent, freed up warehouse space and improved operator safety, resulting in a scalable solution that is ready to support future growth.

Frequently Asked Questions about the Exotec Sequencing Buffer