Lyreco automates its Vottem warehouse with Exotec’s Skypod system

By deploying Exotec’s Skypod® system at its Vottem site, Lyreco has integrated 7,000 additional SKUs into its warehouse, reached a throughput of 1,200 lines per hour, and significantly improved working conditions for its operators. All without interrupting operations.

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Founded nearly 100 years ago, Lyreco is one of the world’s leading distributors of supplies and solutions for businesses, with a presence across Europe and Asia. Its offering, long focused on office supplies, has expanded considerably to cover categories as varied as hygiene, cleaning, and personal protective equipment (PPE).

In the Benelux region, this growth accelerated with the acquisition of Intersafe, a Dutch PPE specialist. A strategic expansion that required Lyreco to fully rethink its logistics site in Vottem, near Liège — the warehouse at the heart of its operations in the region.

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Before the transformation, the Vottem site faced several major constraints that limited its ability to keep pace with the company’s development.

Insufficient storage capacity

The arrival of product lines from Intersafe significantly increased the number of SKUs to manage. The warehouse, in its original configuration, no longer had the capacity to absorb this additional volume. Storing and efficiently retrieving thousands of new references with the existing equipment had become impossible.

Outdated equipment

The existing infrastructure, designed for different volumes and rhythms, no longer met current productivity requirements. Operators were walking long distances to pick orders, which increased physical strain and limited operational flexibility.

Insufficient agility to handle peak demand

In a context where order volumes fluctuate and delivery lead times are tightening, the site lacked responsiveness. Quickly absorbing a surge in activity or adapting production to different order types was a daily challenge

Faced with these issues, Lyreco needed a solution that could simultaneously address three requirements: increase storage density, improve order picking productivity, and enhance working conditions — without overhauling the existing infrastructure.

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The Skypod system proved to be the right fit for Lyreco’s needs. Modular, high-density, and designed to integrate into existing logistics environments, it connected directly to the conveyors already in place at the Vottem site.

“Since installing the Exotec solution, Lyreco has become much more flexible in how it manages production. They can absorb spikes in volume quite quickly and adapt to different order profiles.”

High-density, flexible storage

The 52,000 rack locations accommodate a far greater volume of SKUs than the previous setup. Stock placement is managed by the robots.

Any location can be accessed within 2 minutes, enabling late order preparation with next-day delivery. The system’s architecture is also scalable: racks and robots can be added at any time without interrupting production.

A redesigned picking process

Order preparation follows a two-step flow. Upstream, large or fast-moving items are picked directly from the conveyor. Downstream, the 5 picking stations — continuously fed by the 79 Skypod robots — allow operators to complete orders with references stored in the Exotec system. The WMS automatically calculates the right carton size for each order. The result: operators no longer move around — the robots come to them.

A simple, guided replenishment process

The put-away process is managed by the WMS and requires no specialist knowledge: the operator picks up an empty tote, scans and places the items, then injects the tote into the system. The Skypod takes it from there.

Maintenance handled by Exotec

Exotec manages all maintenance. Over 90% of corrective interventions are carried out remotely from the Control Center in Lille. Critical spare parts are kept on site to ensure operational continuity, and a monthly performance review is held between both teams.

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Commissioning the Skypod system produced concrete improvements across the three priority areas.

Storage capacity

7,000 additional SKUs — brought in directly from the Intersafe acquisition — were integrated into the warehouse with no wall extensions or replacement of the existing conveyor infrastructure.

Productivity

The site now reaches 1,200 picked lines per hour with 5 stations and 79 robots.

“No more walking long distances — the goods come to you. It’s not about being replaced by a robot; it’s about making the job a whole lot easier.”

Working conditions

Operators no longer walk long distances through the warehouse. Picking stations are ergonomic, tasks are screen-guided, and physical strain has dropped significantly.

This change, developed in consultation with floor teams, has been well received.