Founded in 1943 in Zaragoza, Spain, Saica is a family-owned business that has since evolved into one of Europe’s leading companies in sustainable solutions for the manufacturing of recycled paper and packaging, as well as waste management and recovery.  

With an annual output of 3.8 million tonnes of recycled paper, Saica Group operates across 11 countries: Spain, France, Italy, Portugal, the United Kingdom, Ireland, Turkey, Luxembourg, the Netherlands, Poland and the United States.  

Since the beginning, Saica Group has upheld strong values rooted in sustainability, consistently seeking innovative ways to lead the transition towards more efficient and environmentally responsible paper production. Landmark initiatives such as the development of MP9 in the 2000s—the world’s first machine capable of producing paper with grammages as low as 75 g/m²—and the inauguration of the first Waste-to-Energy Plant in El Burgo de Ebro (Zaragoza, Spain), which diverts 450,000 tonnes of waste from landfill, exemplify the group’s unwavering commitment to innovation, environmental stewardship, and delivering customer-focused solutions. Read more at Saica.com.

Spinning into more sustainable and efficient operations 

In 2012, Saica extended its international presence by opening a cutting-edge paper mill in Partington, United Kingdom—the Saica PM11. To maximise operational efficiency and space utilisation, the facility adopted automation from an early stage, incorporating 11 AGVs, which helped Saica achieve additional safety at the PM11 site.  

However, while automation proved to be the right decision, the system’s capacity soon revealed certain limitations. This led Saica to seek a new partner capable of boosting both the performance and scalability of its AGV operations. In 2022, the site transitioned its existing system to Rocla AGV Solutions to meet these evolving demands and scaled the system from 11 to 13 AGVs. 

The capacity of Rocla AGV’s is much, much higher than our previous AGVs’ – Pasi Häyrynen, PM11 Plant Manager.  

Solution specifications 

The show must go on; COVID-19 couldn’t stop us  

The entire process took place during the height of the global pandemic, a period marked by significant travel restrictions that limited the team’s ability to visit the PM11 site in Partington. 

This posed a considerable challenge for all involved parties. “A project of this scale typically requires multiple on-site visits and in-person meetings to thoroughly assess existing processes, understand customer objectives, and address key project requirements. Equally important was the need for us to see the AGVs in action and gain a deeper understanding of the product”, explains Mark Elferink, Lean Projects Manager. 

Nevertheless, Elferink highlighted that our extensive experience and expertise in intralogistics automation, combined with a strong track record in paper material handling, enabled Saica to gain a deeper understanding of Rocla AGV Solutions and place their trust in us as a partner. 

A process that keeps the business rolling optimally 

To enhance operational efficiency, we conducted a thorough analysis of the existing processes and developed a tailored solution consisting of 13 Rocla AWThsc vehicles, an automatic battery exchange system, our in-house developed FleetController software and MetRo warehouse management system (WMS), and our Full service package. 

We opted for the heavy AWT model for its impressive specifications, including a maximum load capacity of 4.5 tonnes and a lifting height of up to 10 metres. However, in line with current stock requirements, the AGVs are currently operating with loads of 4.4 tonnes and stacking them to a height of 10 metres.  

The AGVs at the PM11 site operate 24/7 on three core functions, enabling full automation of the reels warehouse: 

To ensure the solution operates around the clock, the AGVs must remain sufficiently charged to maintain optimal performance. However, manually changing the heavy batteries can lead to downtime and pose ergonomic risks for workers. Thanks to the automatic battery exchange system, each AGV monitors its battery level and, upon reaching 30%, completes its current task before autonomously navigating to the automated battery exchange station. There, it’s directed to the most suitably charged battery and is ready to resume operations in no time, minimising disruption and maximising efficiency. 

As a solutions provider, we addressed the customer’s needs by delivering our MetRo warehouse management system (WMS). MetRo streamlines stock administration by automatically updating inventory levels and automating housekeeping, thereby improving administrative efficiency. Like other advanced WMS platforms, MetRo integrates seamlessly with the existing MES or ERP system. The flawless communication with FleetController the software ensures smooth and reliable communication between the host system and the AGVs. 

FleetController intelligently allocates tasks to minimise downtime by selecting the most suitable AGV for each operation. With the RouteOptimizer, it can also anticipate and plan the most efficient routes by analysing real-time conditions across different warehouse aisles, guiding AGVs along the optimal paths. Managers can monitor live operations anytime or review historical activity and status events via the FleetController Dashboard from the control room. 

Timely response through our local services team in the UK 

Ensuring the smooth operation of our solutions is a key part of our commitment to more sustainable intralogistics. By delivering robust, long-lasting systems, we help minimise unnecessary waste and the associated costs. Our comprehensive service packages allow us to monitor performance, carry out regular maintenance, and provide timely upgrades, extending the lifespan of the AGV solution and maximising its value over time. 

Timely responses to potential risks can help avoid costly repairs and replacements. Choosing the right service package is crucial to ensuring the longevity of your AGV fleet. It also guarantees that the solution continues to support smooth operations and high productivity, with AGVs functioning safely, reliably, and efficiently. 

With sustainability and longevity in mind, Saica opted for our Full service package as it best suited their needs. The Full service package includes  

As a cornerstone of Mitsubishi Logisnext Europe’s service and support offering, we provide both global and local maintenance operations, available 24/7.  Leveraging our extensive network, we provide localised support to Saica through Logisnext UK, ensuring responsive customer service and rapid on-site assistance. “Typically, Logisnext UK Services attends the site within 24 hours of a call being logged, and we have a good rapport with the engineers who attend the site from the services department in the UK”, says Robert Evans, Internal Logistics Manager at Saica PM11.  

Results 

With automation in place, Saica has achieved greater safety, transparency, and traceability across its 24/7 operations. The implementation of Rocla AGV Solutions marked a significant upgrade from the previous system, offering substantially higher capacity that translated into improved efficiency and cost savings. Despite the challenges posed by travel restrictions during the pandemic, “the solution exceeded all our expectations,” says Elferink. 

As a comprehensive solutions provider, we supported Saica throughout the entire process, delivering not only the AGV system but also the warehouse management system and associated services. By managing the project end-to-end, we eliminated the complexity and stress of coordinating multiple suppliers. 

Ensuring the reliable performance of automated guided vehicle (AGV) systems is key to advancing sustainable intralogistics. In this case, Saica benefits from prompt, localised support through Logisnext UK, ensuring reliable service and strong working relationships. 

Our industry expertise, robust and efficient AGV solution, paired with advanced software, tailored services, and a collaborative partnership, has enabled Saica to continue meeting its sustainability targets without experiencing downtime, which is one of the most significant improvements since the upgrade, according to Häyrynen.  

As Saica looks to the future, discussions are already underway around solutions to optimise storage capacity within the warehouse. Evans has expressed full confidence in Rocla AGV Solutions, reaffirming it as their preferred partner for the next development phase.