Unique total integration for peak periods at Smartphoto

About smartphoto

Smartphoto is one of the largest European players in digital photo processing, sending up to 2.7 million personalized packages across Europe every year. The logistical pressure increased, especially during peak periods.

The logistical challenge

During the year-end period, the order volume rose to a factor of 8. Manual processes were not scalable and resulted in high personnel costs, long walking distances and increased shipping costs due to split orders.

Vanas's solution

For Smartphoto, Vanas designed a unique total integration that is specifically tailored to extreme seasonal peaks and a highly fluctuating order volume. The goal was to seamlessly connect production, sorting and packaging to create a scalable logistics process that remains stable and efficient even during peak periods.

The solution starts from cleverly linking the production environment on the second floor with the packaging department on the ground floor. This is done via two vertical Modula lifts with inbound and outbound drawer openings on both sides. Finished products are placed in the lift directly from production and automatically transported downstairs, where they are consolidated per order via a pigeonhole sorting system.

Thanks to this configuration, multiple items can be processed per drawer at the same time, resulting in an exceptionally high speed. During peak periods, the lifts perform up to 800 manipulations per hour per lift — an exceptional performance for this type of system. During this period, the lifts are operational 24/7 and form the beating heart of the logistics process.

After consolidation, orders are automatically transferred to an Active Roller Belt (ARB) sorter with a capacity of up to 3,000 packages per hour. This sorter minimizes errors and ensures that packages are properly labeled and directed to the correct shipping stream.

The packaging department was also completely redesigned. Vanas developed a compact, ergonomic packing setup with conveyors at various heights, linked to custom-made packing tables. This allows all actions to take place within arm's radius, which not only drastically reduces walking distance, but also significantly improves the ergonomics and productivity of employees.

The result is a robust, scalable logistics system that enables Smartphoto to handle peak volumes with significantly fewer staff, without sacrificing speed, quality or reliability.

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Results and impact

Quickness

• Up to 800 manipulations per hour per lift
• 3,000 parcels per hour via the sorter

Economical

• Van 20 to 8 employees during peak periods

Ergonomics

• All actions within arm radius
• Greatly reduced walking distance

Save space

• Van 200 m² to 40 m² for buffer section

Why Smartphoto chose Vanas

Smartphoto especially appreciates the customization and the input. Vanas did not think in terms of standard solutions, but in what really worked operationally — even during extreme peaks.

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