Rondo Ganahl Aktiengesellschaft is a traditional Austrian family business with 220 years of history. The core business of the internationally active corrugated board specialists is the production of corrugated board packaging, corrugated board base papers and the collection of paper and packaging. The corrugated board plant in Frastanz (Vorarlberg), Austria, produces corrugated base papers on the basis of 100% recovered paper and, with white and flamed testliner grades, plays a leading role in the main markets of Germany and Austria. For the storage of finished goods, HÖRMANN Logistik has built a new high-bay warehouse with automatic production connection and shipping area, which was planned by Gutweniger Logistik GmbH.

Concept

The new 8-aisle high-bay warehouse (HRL) stores a wide variety of pallet formats made of wood or plastic. The HRL is used for production disposal, for delivery to and disposal from the picking areas, for the storage of merchandise and for the retrieval of goods for dispatch.

The pallets are loaded according to article, with the smaller pallet formats being stored in aisles 1-7, each of which is transported by a channel truck. A special stacker crane with four telescopic forks operates in aisle 8, which can store and retrieve large formats up to 3.1 m long. The pallets from production are transported from there via a conveyor bridge towards the high-bay warehouse. The goods required for picking are processed in order sequence. For this purpose, the storage and retrieval machines (SRM) of aisles 1-7 retrieve the goods on the first floor and then serve them to SRM 8, which transports the pallets to the upper floor, where they are transferred to the conveyor system to the picking areas.

For dispatch staging, the WMS HiLIS cleverly selects the required pallets in the correct retrieval sequence, achieving optimal warehouse performance. The pallets are retrieved by the SRMs and staged at the eight loading lane groups, each with two lanes. HiLIS assigns a loading lane group to each tour (truck). Medium and wide pallets occupy both lanes, smaller pallets only one lane.

The high-bay warehouse operates parallel to the operating hours of the corrugated board plant, 6 days a week, around the clock.  The system performance was designed to meet the requirements of production disposal, order picking supply and shipping performance. Warehouse management and control is carried out with the proven Hörmann intra Logistics System HiLIS, which communicates with the customer system via interface. Thanks to the HiLIS ECO power management system, the stacker cranes save up to 25% of energy consumption through intelligent energy balancing.

Highlights

•     8-aisle high-bay warehouse 74 x 70 x 29 m (L x W x H)
•     7 stacker cranes, each with a battery-powered channel truck
•     1 stacker crane for large formats with four telescopic forks
•     Storage capacity approx. 20,000 pallets
•     Max. Storage capacity 180 pallets per hour
•     Max. Retrieval capacity 25 pallets per hour

Das Hochregallager arbeitet parallel zu den Betriebszeiten des Wellpappenwerks an 6 Tagen die Woche, rund um die Uhr.  Die Anlagenleistung wurde auf die Anforderungen der Produktionsentsorgung, der Kommissionier-versorgung und der Versandleistung ausgelegt. Die Lagerverwaltung und –steuerung erfolgt mit dem bewährten Hörmann intra Logistics System HiLIS, das mit dem Kundensystem über Schnittstelle kommuniziert. Durch das HiLIS ECO-Powermanagementsystem sparen die Regalbediengeräte durch intelligenten Energieausgleich bis zu 25% des Energieverbrauchs.

Highlights

• 8-gassiges Hochregallager 74 x 70 x 29 m (L x B x H)
• 7 Regalbediengeräte mit je einem batteriebetriebenen Kanalfahrzeug
• 1 Regalbediengerät für Großformate mit vier Teleskopgabelzinken
• Stellplatzkapazität ca. 20.000 Paletten
• Max. Einlagerleistung 180 Paletten pro Stunde
• Max. Auslagerleistung 25 Paletten pro Stunde

ZURÜCK ZU DEN REFERENZEN

As one of the world's leading manufacturers in the packaging technology sector, Theegarten-Pactec GmbH & Co. KG develops high-quality and intelligent packaging machines. With innovative strength and premium quality, Theegarten-Pactec has specialized in small-part articles in the food and non-food sectors. At the company's headquarters in Dresden, an efficient automatic small parts warehouse was to be built to supply the assembly of packaging machines. HÖRMANN Logistik implemented an AutoStore® solution for the special spatial conditions and material flow requirements.

Concept

The control and recording of the delivered goods takes place at the goods receiving area. The quantities for AutoStore® storage are provided at the AutoStore® picking stations. As soon as a space becomes available in an AutoStore® bins, the picking employee stores an item and books it into the open AutoStore® bins waiting at the picking station. In this way, up to 60 items per hour are stored and a continuously high tote fill level is guaranteed. At the same time, the number of tote movements is kept to a minimum. If required, suitable AutoStore® bins can also be actively requested for storage. In this case, the WMS system selects the AutoStore® bin that has the corresponding free volume, can accommodate the incoming storage weight, and can be retrieved most quickly.

Intelligent algorithms optimize the movement of goods

In total, Theegarten-Pactec's AutoStore® warehouse comprises a good 14,000 bins, 6 robots and 3 storage/picking workstations. All goods movements within the AutoStore® system take place in a self-optimizing process. With help of an intelligent algorithm, reallocations within a stack begin in good time before the bin in question is transported for picking. At the same time, bins with less frequently used items sink steadily further down, while items with frequent accesses remain permanently at the top. In this way, the picking modules can be supplied with bins optimally and without waiting times for approx. 90 processes per hour.

ZURÜCK ZU DEN REFERENZEN