Industrial Automation | FMCG Distribution Centre | North India
FMCG Warehouse Automation Case Study: 269 Installations Across Two Distribution Centres in 4 Months
269+ Installations | 2 Distribution Centres | 4-Month Delivery Timeline
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2 Large Scale Distribution Centres Across 2 States
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269+ Units Installed
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Completed in 4 Months
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CE Certified Dock Levellers as per EN 1398:2009
When a leading global FMCG company planned two large-scale distribution centres in North India, it required a partner capable of delivering reliable warehouse automation solutions while maintaining strict quality standards and aggressive project timelines.
The project involved the complete design, manufacture, supply, installation, and commissioning of critical loading bay equipment across facilities in Jhajjar, Haryana, and Haridwar, Uttarakhand. As an experienced dock leveler manufacturer in India, Aurotoshi was selected to execute the complete scope, providing a single point of responsibility across both sites.
The successful completion of 269 installations within four months helped establish efficient loading and unloading operations for facilities designed to support high-volume logistics and distribution activities.
About the Project
Two New Warehouses. One Partner for Everything.
A leading global FMCG company was setting up two new distribution centres in North India: one in Jhajjar, Haryana, and one in Haridwar, Uttarakhand. Both facilities were large-scale warehouses designed to handle significant daily movement of goods and support continuous logistics operations.
To simplify project execution and maintain consistent quality standards across both locations, the client appointed Aurotoshi as a single-source partner for warehouse automation solutions, loading dock equipment, access systems, and safety infrastructure.
How Aurotoshi Was Selected
A Three-Step Approval Process Before Any Order Was Placed
This organisation follows a structured vendor qualification process and does not make procurement decisions based solely on price. Before any commercial approval was granted, Aurotoshi successfully completed all three stages of evaluation.
Step 1: Proof of Concept
Aurotoshi designed, supplied, and installed one dock leveller, one motorised shutter, and one fire-rated door at the project site.
The client evaluated the equipment under actual operating conditions for a full month. After verifying product quality, reliability, and performance, formal approval was provided to move to the next stage.
Step 2: Factory Visit
The client’s team visited Aurotoshi’s manufacturing facility in Ghaziabad to assess production capabilities, quality processes, and manufacturing standards.
Following a detailed review of operations, approval was granted to proceed with procurement.
Step 3: Technical Documentation Review
Technical drawings, product specifications, certifications, and supporting documentation were submitted and reviewed before final order confirmation.
A key factor in Aurotoshi’s approval was its CE-certified dock levellers manufactured in compliance with EN 1398:2009 standards and physically tested by TÜV Nord.
Aurotoshi is one of only three manufacturers in India with this certification. Its dock levellers have undergone physical load testing at dynamic loads exceeding 12 tonnes, demonstrating their suitability for demanding industrial environments.
What Was Supplied and Installed
All Six Product Categories. Both Plants. One Execution Partner.
The complete scope covering design, manufacturing, supply, installation, and commissioning was executed by Aurotoshi.
|
Product |
Jhajjar, Haryana |
Haridwar, Uttarakhand |
|
Industrial Shutters |
82 |
75 |
|
Dock Levellers |
60 |
60 |
|
High-Speed Entrance Gates |
2 |
2 |
|
Boom Barriers |
2 |
— |
|
Fire-Rated Doors |
36 |
— |
|
HMPS Doors |
9 |
— |
|
Total |
191 |
137 |
All products were manufactured at Aurotoshi’s facilities in Ghaziabad and delivered under a unified project execution plan.
Delivery Timeline
Completed in 4 Months
Projects involving multiple vendors often face scheduling conflicts, coordination challenges, and extended implementation timelines.
By managing manufacturing, supply, installation, and commissioning internally, Aurotoshi maintained complete control over project execution and eliminated coordination gaps.
From design approval to final handover across both facilities, the entire project was completed within four months.
Industry projects of similar scale frequently require six to eight months for completion.
Why Delays Were Not an Option
These distribution centres operate at a scale where uninterrupted loading bay performance is essential.
The facilities handle approximately 700 to 800 truck movements per day across 60 loading bays operating at more than 70% utilisation.
Even a single loading bay being unavailable for one day could prevent approximately 30 truckloads of goods from reaching their intended destinations.
Across an operation of this size, delays can have a significant impact on supply chain efficiency, inventory movement, and customer fulfilment.
Why the Project Succeeded
Aurotoshi’s OEM manufacturing capability played a critical role in the success of this project.
Unlike many solution providers that depend heavily on third-party suppliers, Aurotoshi manufactures its products in-house across multiple facilities in Ghaziabad.
This provided the client with complete visibility into manufacturing quality, production schedules, testing procedures, and delivery timelines.
More importantly, it ensured a single point of accountability from vendor qualification and factory audits through to installation and final commissioning.
Project Outcome
This project demonstrates how the right combination of engineering expertise, certified products, manufacturing capability, and project execution can help large distribution centres achieve operational readiness without compromising quality or timelines.
By delivering 269 installations across two FMCG distribution centres in just four months, Aurotoshi successfully provided a complete warehouse automation solution under a single execution plan while ensuring reliable loading bay operations for a high-volume distribution network.
Key Project Highlights
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269+ Installations Completed
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2 Distribution Centres Across North India
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4-Month Project Completion
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CE Certified Dock Levellers (EN 1398:2009)
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TÜV Nord Tested Dock Levellers
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Dynamic Load Testing Exceeding 12 Tonnes
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Single-Source Project Execution
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Facilities Supporting 700-800 Truck Movements Daily
Frequently Asked Questions
What is a dock leveller and how does it work?
A dock leveller is a platform installed at a loading bay that bridges the gap between a warehouse floor and a vehicle. It creates a safe and stable surface for forklifts and material handling equipment during loading and unloading operations.
Why is loading bay equipment important for warehouses?
Loading bay equipment helps improve safety, reduce loading times, increase operational efficiency, and support smoother movement of goods between vehicles and warehouse facilities.
What should businesses consider when choosing a dock leveler manufacturer in India?
When selecting a dock leveler manufacturer in India, businesses should evaluate product quality, safety certifications, manufacturing capability, compliance with industry standards, installation expertise, and long-term service support.
What is the purpose of loading dock equipment in a distribution centre?
Loading dock equipment enables efficient transfer of goods between transportation vehicles and warehouse facilities. Properly designed systems help minimise delays, improve productivity, and reduce operational risks.
How can warehouse automation solutions improve logistics efficiency?
Warehouse automation solutions help streamline material movement, reduce manual processes, improve loading speed, minimise downtime, and support better overall supply chain performance.
Setting Up a Warehouse or Distribution Centre?
Talk to Aurotoshi.
We design, manufacture, supply, install, and commission complete loading bay equipment and warehouse automation solutions under one execution plan.
sales@aurotoshi.com | +91 9711186186 | www.aurotoshi.com
Aurotoshi (An Aurionpro Company) – Entrance Automation OEM Since 1992.
