Lyreco Optimizes Its Logistics With Exotec's Sequencing Buffer

At its long-standing distribution center in Villaines-la-Juhel (Mayenne), Lyreco deployed Exotec’s sequencing buffer to replace an outdated sorting machine. The result: preparation time for the 200 to 300 daily pallets dropped from 14 to 7 hours (with a single shift), doubling productivity.

The new system, three times more compact than the old one, also freed up 8,000 m² of operational space. Thanks to a sequencing algorithm developed by Exotec, packages now come out in the correct order, from heaviest to lightest, resulting in more stable and safer pallets, while eliminating manual load-carrying for operators.

The system relies on 105 robots, 22,000 storage slots, 6 Exchangers, and 5 palletizing wells, delivering a throughput of 3,200 packages per hour.

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Established for over 55 years in Villaines-la-Juhel, Mayenne, the Lyreco distribution center is a historic site at the heart of the group’s supply chain. Its mission: receive goods, store them, and prepare orders for next-morning delivery to the last-mile centers responsible for delivering to the company’s stores. This strong commitment demands a sustained pace: 5,500 orders processed daily, representing 35,000 order lines and nearly 25,000 packages per day.

Faced with natural equipment obsolescence and growing performance requirements, Lyreco chose to trust Exotec to replace its aging sorting machine with a modern solution capable of simultaneously addressing productivity, ergonomics, and service quality challenges.

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An outdated sorting system

The old installation could no longer keep pace with the site’s growing demands. Palletizing the 200 to 300 pallets sent daily to the last-mile centers required two shifts working 14 hours.

Increased risk of musculoskeletal disorders (MSDs)

Under the old setup, operators had to manually handle packages weighing several kilograms each. Carrying, moving, and then placing these loads on the ground or at height on pallets throughout the day created MSD risks and increased fatigue among teams.

Less stable pallets, a source of risk

Without a sequencing algorithm, the order in which packages came out was also uncontrolled. Heavy packages were sometimes placed at the top of a pallet, compromising its stability.

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Exotec deployed a pure buffer system at the Villaines-la-Juhel site: packages enter the system throughout the day’s production, are stored in one of the system’s 22,000 slots, then come out at the end of the day to feed the palletizing wells — in the correct order.

This mode of operation allows Lyreco to produce freely throughout the day and trigger just-in-time palletizing at truck departure time.

“The big difference between the old sorting machine and the new Exotec solution is the ergonomics.”

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The buffer is sized to absorb the site’s entire daily production. The larger the stock at launch time, the more freedom the algorithm has to build optimal pallets.

This algorithm, developed entirely in-house by Exotec’s software teams, determines the order in which packages exit to ensure well-structured pallets: the heaviest packages at the bottom, medium ones in the middle, and light, fragile ones on top.

“The pure buffer solution would have served no purpose if we hadn’t built in the intelligence to release packages in the right order. That’s what we achieved with our software teams.”

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Designed in partnership with Elten, the five palletizing wells were designed to eliminate the most strenuous movements. The package arrives directly to the operator via a conveyor and spiral chute. The operator then slides it onto the pallet. The pallet itself gradually descends into a well as it’s built, so the operator always works at a comfortable height.

Once the pallet is complete, the operator moves it out: a safety gate closes automatically, the pallet is wrapped, labeled with its destination, weight, and traceability barcode, then transferred directly to the loading dock.

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Productivity x2

Where the old machine required 14 hours and two shifts to palletize the 200 to 300 daily pallets, the Exotec system achieves the same volume in 7 hours — a 100% productivity gain that considerably lightens the site’s organizational load and supports its ongoing skills development plan.

8,000 m² freed up

Exotec’s sequencing buffer takes up three times less space than the previous system. This compactness allows Lyreco to reclaim 8,000 m² of space within its existing building, available for new activities or to support the site’s future growth.

Transformed ergonomics

Operators no longer carry packages. They always work at the same height, sliding packages across the work surface, and no longer need to perform the twisting or lifting motions that caused fatigue and MSD risks. A concrete transformation of daily work life, accompanied by a noticeable reduction in warehouse travel, while also improving team diversity.

Higher-quality, safer pallets

Thanks to the sequencing algorithm, every pallet follows a rigorous structure: heaviest to lightest, from base to top. Pallets are more stable during transport, and the risks associated with unloading at the last-mile centers’ docks are reduced.

“A partnership is a relationship of trust between two companies that must work together to achieve the goal set out in the contract. That’s what Lyreco and Exotec are doing — together.”