Fermator upgrades intralogistics with MiR1200 Pallet Jack

Global elevator door manufacturer Fermator optimized internal material transport between warehouse and production lines at its Falset plant (Tarragona, Spain) by deploying the MiR1200 Pallet Jack.

At a glance

• Automated internal transport between warehouse and production

• Increased workplace safety and more predictable transport flows

• Enabled continuous route optimization through AI-based navigation

• Freed operators from repetitive tasks to focus on higher‑value work

The AI-enabled MiR1200 Pallet Jack was selected for its free navigation, fast deployment without infrastructure changes, and ability to adapt to multiple pallet and container types, enabling Fermator to automate transport without disrupting existing operations. 

The project, implemented by MTS Tech, increased the company’s workplace safety, enabled continuous route optimization, and freed operators from repetitive transport tasks so they could focus on higher‑value work. 

Company overview 

• Global manufacturer of automatic elevator doors 

• 12 production plants worldwide 

• Approximately 1,900 employees 

• Produces around 700,000 doors annually 

Founded in Reus (Tarragona) in 1977, Fermator is a family‑owned company specializing in automatic elevator doors. Over time, it has grown from a national pioneer into a global market leader, operating 12 manufacturing plants worldwide with approximately 1,900 employees. Annual production reaches around 700,000 doors, representing about 20% of the global market. 

Safety is a core pillar of Fermator’s business. 

“When we talk about transport, we often think of rail or maritime transport, but vertical transport also exists,” explains Eduard Amigó, Commercial Director and Co‑CEO of the group. “Elevators are a means of transport used every day by millions of people worldwide.” 

Key challenges 

• Manual transport using forklifts and operator‑driven vehicles 

• Safety risks from manual driving in internal logistics 

• Inconsistent and unpredictable transport times 

• Need for smoother material flow between production stages 

• Requirement to improve efficiency without disrupting operations 

At the Falset plant—dedicated to commodity doors for new elevator installations—the internal flow of materials between production areas and process stages was inefficient. Before automation, pallets were moved using forklifts and manually operated vehicles. 

While the facility layout was orderly, Fermator needed a smarter, safer, and more predictable route from goods reception to final packaging. Manual driving caused safety risks and inconsistent transport times. 

“In contrast, the Pallet Jack calculates the route, knows exactly where to go, and always follows consistent patterns and paths,” says Jordi Marco, Industrial Programmer at Fermator. “What we wanted was a smoother flow from point A to point B, without interruptions or repetitive tasks.”

 Remote visibility 

• Transport missions can be monitored remotely 

• Access available from office or anywhere on the factory floor 

Through MTS Tech’s application, every mission can also be monitored remotely, from an office or anywhere on the factory floor. 

Solution overview 

• AI-enabled autonomous mobile robot (AMR) 

• Free navigation with real-time decision-making 

• No infrastructure changes required 

• Designed for dynamic production environments 

Choosing the right solution required a rigorous evaluation. 

“We had a responsibility to evaluate what the market could offer,” says Amigó. “We met with several companies, but when we spoke with MTS, they clearly understood our company’s DNA, where we could improve, and they proposed solutions we hadn’t seen elsewhere in the sector.” 

This confidence was reinforced by prior collaboration: Fermator already had MiR robots operating in other group plants, also implemented by MTS Tech. 

Implementation approach 

• Project analysis to define requirements 

• Selection of the most suitable solution per workflow 

According to Toni Jurado, Technical Director and Co‑Founder of MTS Tech, the approach is clear: 
“We start with a project analysis and then define the most suitable machine for each process.” 

Selected solution 

• MiR1200 Pallet Jack 

• AI-enabled pallet handling 

• Transports up to 1,200 kg 

• Picks and delivers pallets directly from the floor 

Following this analysis, the decision was straightforward. Fermator selected the MiR1200 Pallet Jack , an AI-enabled autonomous mobile robot designed to pick up and deliver pallets directly from the floor—without additional infrastructure—and with a payload capacity of up to 1,200 kg. 

Key capabilities 

• Real-time route optimization 

• Autonomous navigation without fixed paths 

• Safe operation in mixed traffic environments 

• Dynamic obstacle detection and avoidance 

The MiR1200 Pallet Jack is powered by AI‑based navigation and perception software that continuously interprets sensor data to understand its surroundings, predict obstacles, and optimize routes in real time. Rather than following fixed paths, the robot makes autonomous driving decisions on the fly, enabling safe, efficient pallet transport in dynamic factory environments.

The AMR is therefore designed for safe collaboration with people. Three laser scanners cover all areas around the robot and dynamically adjust its speed based on the surrounding environment, ensuring safe operation alongside plant personnel. 

Key advantages 

• Autonomous decision‑making and rerouting 

• Flexible operation without predefined paths 

• Adaptability to changing factory conditions 

One of the key differentiators for Fermator was MiR’s free navigation system. 

“The system determines the best path from origin to destination while avoiding obstacles—it makes its own decisions,” explains Amigó. “That flexibility means that if an obstacle appears, the robot automatically reroutes through an adjacent aisle that wasn’t originally planned.” 

Adaptability to different load carriers was another decisive factor. Fermator works with a wide variety of pallet and container types. 

Handling multiple load types 

Flexibility in operations:

• Works with a wide variety of pallet types 

• Supports non-standard containers 

• Adapts to real production variability 

“We’re not limited to standard Euro or US pallets; we can work with different container types in motion,” Amigó adds. 

Implementation process 

Deployment required no construction work or plant modifications. Implementation followed four clear steps: 

• Mapping the work area 

• Defining restricted zones and preferred routes 

• Configuring pickup and drop‑off points 

• Programming missions 

“We had to teach the robot to identify which pallet it needs in each situation,” Amigó explains. 

Ease of use 

• Intuitive user interface 

• Simple programming 

• Fast updates—changes in under 30 seconds 

The software and user interface further supported adoption. Fermator describes it as intuitive, with simple programming and the ability to modify a location or movement in less than 30 seconds. 

At a glance 

• Increased safety and more predictable transport 

• More consistent transport times 

• Reduced manual workload 

• Greater focus on higher‑value tasks 

Higher safety and more available talent

The results were immediate and measurable. 

“At Fermator, we are committed to safety and efficiency. The Pallet Jack has allowed us to increase our safety target” says Marco. 

Transport movements are now smoother and more predictable. 

“With the Pallet Jack, movements are much easier, and transport times—previously variable—are now more consistent because the most efficient route is always selected,” he adds. 

Impact on people

Operator benefits 

• Reduced repetitive transport tasks 

• Improved ergonomic working conditions 

• Reallocation to higher‑value activities 

The impact on people is equally important. Amigó frames it within a People First philosophy: 

“Employees who used to spend a lot of time on these tasks can now focus on higher‑value activities. We will always need people—robots are here to make our processes easier.” 

Future outlook 

• Expansion to additional Fermator plants 

• Replication of proven results 

• Potential deployment of multi‑robot fleets 

The success at the Falset plant is the starting point for expansion across the Fermator group. 

“This is the first plant where we’ve implemented it, but given the results so far, we’re confident we can replicate it in other factories,” says Amigó. 

Future expansion would involve MiR Fleet, the fleet management system that coordinates multiple robots and assigns tasks based on availability, resources, and configuration—without requiring infrastructure changes. 

Automation challenges addressed

• Optimization of routes and transport times to reduce variability 

• Adaptation to multiple pallet and container types 

• Achieve up to a 90% performance level against internal safety KPIs, compared with approximately 60% before automation 

• Better utilization of skilled labor through reduced repetitive tasks 

Key value drivers

• Intuitive software with configuration changes in under 30 seconds 

• Free navigation for autonomous, efficient obstacle avoidance 

• Remote monitoring and management from anywhere in the facility 

• Compatibility with multiple pallet and container types 

• Scalable expansion with MiR Fleet without construction work 

Tasks automated

• Internal material transport 

• Intralogistics management