Galea Doubles Industrial Storage Capacity with Modula Vertical Lift Modules

Galea Case Study Summary

For over 45 years, Galea has provided technical solutions for high-stakes sectors such as oil & gas, naval, and railway industries. Facing a warehouse at maximum capacity, the company installed four Modula Lift VLMs (two MX50 and two MC50 models). This strategic investment allowed Galea to double its storage capacity on the same footprint, automate the management of 70% of its references, and achieve total real-time traceability while significantly enhancing operator safety.

The Challenge

As Galea’s customer base grew to over 1,000 global clients, its traditional storage system reached a critical limit. The warehouse relied on conventional pallet racking reaching heights of 33 feet (10 meters), which required operators to navigate long distances and use reach trucks for every pallet movement. This manual routine was not only time-consuming but also presented ergonomic challenges, as many industrial components exceed 110 lbs (50 kg). The company needed a faster, more accurate way to handle heavy loads without expanding its physical warehouse boundaries or interrupting daily operations.

“Previously, operations were more manual and demanding… moving pallets with the forklift was part of the daily routine. Today, we work faster, more efficiently, and with greater accuracy,” notes the Galea management team.

The Solution

Galea modernized its logistics by installing four Modula Lift units, specifically choosing a mix of MX50 and MC50 models to accommodate diverse inventory sizes. The complete system provides a total of 171 trays with lengths of 98 inches (2.5 m) and 122 inches (3.1 m). Each tray is capable of supporting up to 1,102 lbs (500 kg), allowing Galea to house 70% of its total references within the units.

The installation was designed with a heavy focus on ergonomics and safety. Each VLM is equipped with a telescopic bay and automatic doors to protect both the operator and the materials. To handle the heaviest industrial parts, Galea integrated overhead rails with electric hoists, allowing for effortless loading and unloading at a constant ergonomic height. On the software side, the Modula WMS communicates directly with Galea’s ERP, while the LED Bar and Copilot console guide operators to the exact item location, eliminating the margin for error.

Key Benefits

The impact of the transformation was immediate. By moving to a vertical “goods-to-person” model, Galea doubled its storage volume without increasing its floor footprint. Picking speeds have increased by 50%, and the combination of visual aids and software integration has led to a 70% reduction in picking errors. Beyond efficiency, the new workflow has transformed the warehouse environment; heavy items are now presented at an ideal working height, removing the physical strain of manual handling and allowing Galea to scale its operations with total confidence.