Soenen Golfkarton NV is a state-of-the-art family business that produces corrugated board on two corrugators and converts it at the same plant into packaging that can be printed with up to seven colors to high quality standards. At the company's headquarters in Hooglede (Belgium), continuous growth necessitated a realignment of internal logistics. Based on its extensive corrugated board experience, HÖRMANN Logistik, as general contractor, developed a convincing, highly flexible logistics concept.

Concept

In the new 6-aisle high-bay warehouse, corrugated board formats, finished corrugated board packaging and empty pallets are stored. One of the main challenges of the high-bay warehouse concept is the very heterogeneous pallet types and sizes (1,200 x 800 to 1,800 x 2,350 mm (L x W), heights up to 2,200 mm) that have to be transported and stored. The resulting requirements for mechanical components, IT and control technology are extremely complex, but have already been implemented several times by HÖRMANN Logistik in this industry. The production connection is made via two conveyor lines on which the pallets are centered, checked for contours and read via the RFID tag. The identified pallets pass through a sorting area. Large-format pallets are fed through, while smaller formats, which account for around 90% of total production, are grouped into pairs. This pairing almost doubles the storage and retrieval capacity. The sorted pallets are transported by an electric overhead conveyor (EHB) towards the high-bay warehouse, where they are delivered to one of the six storage aisles. Each EHB aisle can hold a pair of pallets. Each of the six aisles of the high-bay warehouse is equipped with a highly dynamic storage and retrieval machine (SRM) with telescopic forks, which can transport up to two pairs (= four pallets) simultaneously. The stacker crane moves the pallets to the position in the high-bay warehouse designated by HiLIS, which is controlled with pinpoint accuracy using camera-based compartment fine positioning. To optimize energy consumption

To optimize energy consumption, all SRMs are equipped with the HiLIS Eco-Power Management System, which saves up to 25% of energy consumption through intelligent energy balancing.

Each SRM has two telescopic forks for quadruple-deep pallet storage in the rack and is equipped with two travel drives to achieve high dynamics. This ensures high acceleration in both directions of travel.

Pallet identification and tracking with RFID technology

For shipping, the pallets are requested by HiLIS, retrieved in pairs as far as possible and delivered to one of the eight shipping lane groups via the EHB. Each shipping lane group has four conveyor lanes on which almost a complete truck load can be provided. A steel plate conveyor that can be driven on allows the loader to pick up the pallets lengthwise or crosswise. The display of the shipping lane group shows the important information for the loader. The entire pallet identification and tracking in the logistics process is carried out using state-of-the-art RFID technology. The RFID tag is already applied fully automatically to the delivered empty pallets. In production, the pallet and the associated production order are "married" by HiLIS. From here, the pallet is tracked via RFID until it is loaded into the truck. Each truck gate is equipped with an RFID gate at which each correctly loaded pallet is recognized and acknowledged as loaded.

Highlights

•     6-aisle high-bay warehouse:212 x 71 x 37 m (L x W x H)
•     Storage capacity: 59,000 pallets
•     Storage / retrieval capacity: 240 / 300 pallets per hour
•     6 stacker cranes
•     Electric overhead conveyor
•     RFID technology
•     HiLIS WMS
•     Storage and transport of different pallet types and sizes without sub-pallet
•     Traceable data management
•     Sequence-accurate dispatch provision

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Progroup produces corrugated sheetboards in its core business with high-tech equipment that is among the fastest in the world. Its own paper production and service companies provide process optimization at 12 locations in Europe. Strongly expanding and highly specialized, Progroup has been working with HÖRMANN Logistik for many years to implement future-oriented intralogistics concepts.

Automated high-bay channel warehouse in Schüttorf, Germany

In Schüttorf/Lower Saxony, Progroup built the largest and most modern corrugated sheet feeder plant in Europe with a corrugator of 3.30 m working width, a speed of up to 400 m/min and a production volume of 140,000 t/a. Between the CIM-controlled corrugated board production (Computer Integrated Manufacturing System) and the shipping department, HÖRMANN Logistik installed a high-bay warehouse with buffer function.

The stacked corrugated board produced on the corrugator is immediately transported away, placed on up to three sub-pallets depending on the order and format, secured against loading and temporarily stored in the high-bay warehouse. Before storage, the load units are measured, centered and aligned. Depending on the specified retrieval date and order assignment, HiLIS decides where the load is to be stored.

Highlights

•     3-aisle high-bay channel storage system with 13 levels and 13,000 storage locations
•     3 highly dynamic stacker cranes in single-mast design with a lifting speed of up to 2 m/s and variable acceleration values
•     Automatic handling of almost all stack dimensions (max. dimension of 2.5 x 1.8 x 2.2 m, with max. 3 lower pallets or palletless)
•     Special channel vehicles for lengthwise or crosswise storage of corrugated board stacks
•     Intelligent pairing strategies with the HiLIS Warehouse Management System
•     Logical quadrant management of the warehouse for performance optimization
•     Millimeter-precise management and positioning of stacks in the channels for optimal volume utilization
•     Shortest provisioning times and flexible loading of approx. 100 trucks per day
•     Storage/retrieval capacity of 120 / 150 units per hr.
•     Operating time of 24 hrs/day and 7 days/week

Automated high-bay channel storage system in Offenbach, Germany

At the Progroup site in Offenbach, a state-of-the-art corrugated sheet feeder plant for the production of heavy-duty corrugated board was built in a new record-breaking construction time of only nine months. In order to ensure the greatest possible flexibility with regard to machine utilization and waste-optimized production, a three-aisle high-bay warehouse with channel technology was also chosen here.

Highlights

•     3-aisle high-bay channel storage system: 60 x 41 x 34.5 m (L x W x H)
•     Highly dynamic stacker cranes with 2 channel trucks for large formats with a lifting speed of up to 2.0 m/s
•     Camera-based fine positioning system with teach-in function
•     Millimeter-precise management and positioning of piles in the channels for optimal volume utilization
•     Storage of formats from 1.2 x 0.8 m to 4.2 x 2.5 m
•     Large format stacks are placed on up to 9 lower pallets

Automated high-bay channel storage system in Strykow, Poland

At Progroup in Strykow, HÖRMANN Logistik built a high-bay warehouse using channel technology as a buffer between corrugated board production and shipping. This enables highly waste-optimized production and just-in-time delivery to customers.

Highlights

•     3-aisle high-bay channel storage system with 13,000 storage locations
•     3 highly dynamic storage and retrieval machines
•     Special channel truck for transport with up to three sub-pallets or palletless
•     Millimeter-accurate, camera-based compartment fine positioning with teach-in function
•     Handling and storage of different formats with and without lower pallet
•     Storage/retrieval capacity 120 / 150 units per hour
•     Average storage time less than 24 hours
•     Direct loading of stacks from conveyor into trucks

Automated high-bay warehouse in Ellesmere Port, Great Britain

A special feature of the intralogistics concept at Progroup in Ellesmere Port is the combination of strapped corrugated board formats on pallets and non-strapped corrugated board formats without a lower pallet. Different compartment types in the high-bay warehouse allow fully flexible and volume-optimized loading with packing units in a wide variety of combinations.

Highlights

•     4-aisle high-bay warehouse: 96.7 x 48.2 x 33 m (L x W x H)
•     4 stacker cranes in 2-mast design
•     2 stacker cranes with 1 load handling device - pair factor 100%
•     2 RBG with 2 load handling devices - packing units in triples
•     storage capacity approx. 14,436 pallets
•     Transport and storage of different formats with and without lower pallet
•     Camera-based compartment fine positioning

Automated high-bay warehouse in Eisfeld / Thuringia, Germany

Highlights

•     3-aisle high-bay warehouse: 89.9 x 37.1 x 35 m (L x W x H)
•     2 stacker cranes with 6 telescopic forks
•     1 stacker crane with 3 telescopic forks
•     Storage capacity approx. 10,563 pallets
•     Transport and storage of different formats with and without bottom pallet
•     Intelligent, volume-optimized storage strategies with HiLIS
•     Camera-based compartment fine positioning

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Green Bay Packaging Inc. specializes in custom corrugated packaging, folding cartons and self-adhesive labels. With its philosophy of producing creative solutions tailored to customer requirements, the Green Bay Wisconsin company is a premium supplier in the USA. More than 3,000 employees work at locations in 15 U.S. states as well as Mexico. As part of a plant expansion at Green Bay's Labelstock Division in Wisconsin, a new high-bay warehouse for paper rolls and shippable palletized goods was built. It is directly connected to the existing coating and cutting lines as well as to the newly created production areas by means of automated guided vehicles (AGV). HÖRMANN Logistik realized the new, imposing high-bay warehouse including the connecting conveyor and handling technology and two different AGV systems as a general contractor.

Concept

The special challenges of the two-aisle channel warehouse were the transport and handling of a wide variety of load units with weights of up to 5 tons. With several innovative developments, such as the different roller manipulators, slave board lowering devices, special AGVs with mandrel pick-up and cross-distribution wagons with powercap technology, HÖRMANN Logistik met all project requirements. This also includes the fully flexible storage and retrieval strategies with three stacker cranes. Paper rolls as well as different types of pallets with finished goods can be stored in each storage channel. In this context, one aisle of the high-bay warehouse (HRL) is equipped with two storage and retrieval machines (SRMs) on one track and one aisle with one SRM.

The stacker cranes are each equipped with two channel trucks that can extend individually (for smaller pallets) or together (for system pallets for heavy rolls). The middle rack unit can be served from both aisles, ensuring a redundant supply of rolls to production. The shelving slices are 2-deep, 4-deep or 6-deep in order to respond flexibly to different article quantities. The widths

of the storage channels vary between 1,000 mm and 2,200 mm for better space utilization. All storage and retrieval machines are equipped with self-learning fine compartment positioning, which allows the channels to be approached with millimeter precision.

In goods receiving, the raw material rolls are placed on the system pallet with a line gantry. In the process, the roll is measured, matched with the notified data, transported to the HRL and stored. When production needs raw material, it requests a selection of rolls via the HÖRMANN intra Logistics System HiLIS, from which HiLIS determines the one that is most easily and quickly accessible for the SRMs. In this way, stock transfers can be avoided. After the SRM has retrieved the roll specified by HiLIS, it is taken to another portal via conveyor technology.

This removes it from the system pallet and sets the roll down for an Automated Guided Vehicle (AGV). The AGV then transports the roll directly to the skate of the unwinder in production. The return journey of the finished coated rolls to the warehouse takes place in reverse order. The HiLIS WMS manages and controls all material flow processes and communicates via interface with the Green Bay HOST. The HiLIS visualization ensures permanent transparency and fast fault diagnosis in the event of a malfunction.

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The Liebensteiner Kartonagenwerk processes corrugated board formats into finished packaging and has made an outstanding name for itself with individual packaging solutions. The family-owned company offers a wide range of products from attractively printed consumer goods packaging to heavy goods and transport packaging. At its site in Plößberg, HÖRMANN Logistik maximised its storage capacity with a new high-bay warehouse and its expansion in a second construction phase. A new raw materials warehouse was also built. Liebensteiner is a pioneer in the corrugated board industry with this state-of-the-art and fully automated warehouse.

Concept

HÖRMANN Logistik took the specific properties of corrugated board into account for the innovative warehouse concept. These are essentially weight and volume. Relatively large volume means that a large number of pallets are produced during production. The relatively low weight, in turn, allows the simultaneous transport of several load units during storage and retrieval. Depending on the pallet size, one to three pallets can be transported simultaneously per storage and retrieval machine (SRM) trip and stored or retrieved with a play of the load handling device. A technology that increases the performance of the stacker crane by almost three times compared to a conventional stacker crane. This immense device performance makes it possible to effectively cover long distances and thus to create large storage capacities through an extremely long high-bay warehouse. The 5-aisle high-bay warehouse is equipped with five fully automatic storage and retrieval machines. It simultaneously supplies the production, accepts finished goods from the production and retrieves finished goods from the shipping area within a specific time window and at the exact unloading point. With the extension of the high-bay warehouse, almost 20,000 additional storage spaces could be gained with the same number of storage and retrieval units. The control and management of the complete system is carried out by the HÖRMANN intra Logistics System HiLIS, which communicates via interface with the Liebensteiner HOST system. According to sophisticated storage strategies, HiLIS calculates the storage location in order to achieve an optimum of short travel times for the SRM, a weight distribution to all aisles and a high degree of warehouse utilization. The HiLIS system visualization supports operation and control of the entire system with simple, ergonomically designed masks in real time. The logistical masterpiece is to fill the dispatch routes for a truck in such a way that the material flows from all warehouses converge there almost synchronously.

Highlights

New building and extension of high-bay warehouse

•     5-aisle high-bay warehouse: 186 or 273 x 46 x 33 m (L x W x H)
•     14 levels with up to 36,000 or 52,000 parking spaces
•     5 storage and retrieval machines in single mast design
•     Flexible, up to triple-deep storage of pallets of different sizes
•     Maximum flexibility with regard to the storage of different load unit sizes with up to three sub-pallets and palletless
•     Use of roller and plastic chain conveyors for gentle pallet transport
•     Retrofit of the existing high-bay warehouse and the existing shipping hall with connection to the new areas
•     Max. size of the loading units 2,800 x 2,200 mm with up to three sub-pallets
•     Single, pair and triple transport
•     Installation of a new warehouse management system with integration of the existing plant components

New high-bay warehouse for raw materials

•     3-aisle high-bay warehouse: 97 x 25 x 13 m (L x W x H)
•     Max. charge dimensions: 3.05 x 2.5 x 1.9 m (L x W x H)
•     Max. load weight: 2 t
•     3 storage and retrieval machines with 8 telescopic forks each
•     Storage/retrieval capacity: 79 LE/h
•     High storage capacity with small footprint
•     Flexible assignment of the shelf compartments
•     Transport and storage without underpallet and load securing
•     Just-in-time delivery for processing
•     Storage capacity up to 1.5 million m²

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Kunert Wellpappe Bad Neustadt GmbH & Co.KG is part of the family-run Kunert Group. Today, the Kunert Group employs 1,900 people in 16 plants in Europe and Asia. Annually, the Kunert Group produces 300,000 tons of corrugated board cores, edge protectors and packaging, as well as over 225,000 tons of corrugated board cores. A new automated high-bay warehouse was built at the Bad Neustadt site to create space for production expansions and to meet changing customer requirements for smaller order quantities, shorter delivery cycles and efficient inventory management. With an innovative concept, HÖRMANN Logistik took over the realization of the new warehouse with connecting conveyor technology. Special feature of the four-aisle channel warehouse is the multiple-deep cross storage of a wide variety of finished goods formats on different types of pallets as well as on several sub-pallets.

Concept

The packing units are transported from production by a distribution trolley for transfer to the new conveyor system. Already in production, care is taken to ensure that, if possible, two identical packing units are always transported one behind the other, which can then be conveyed as pairs in the high-bay warehouse area and stored and retrieved. This significantly increases the throughput of the warehouse. A packing unit can have up to six sub-pallets. The packing units are centered and checked for length, width, height, pallet width, pallet length and weight via a contour control system.

The conveyor system then brings the packing units to the prezone of the high-bay warehouse, where a pallet circuit with special chain conveyors and roller lifting tables connects the production, high-bay warehouse and shipping preparation areas. For storage in the new channel warehouse, the packing units are precisely positioned at the storage spur with the aid of a light grid. The two-mast storage and retrieval machines (SRMs) are equipped with chain conveyors and channel trucks. In two aisles of the warehouse, the SRMs operate with one channel truck each, while in the other two aisles they operate with two channel trucks each to handle the transport of large pallets.

The channel trucks are battery-powered and are charged on the fly at the AS/RS. The stacker crane picks up the packing unit crosswise and stores it multiple depths in the storage channels with the help of the channel trucks. During order-related retrieval, the HiLIS warehouse management and control system receives a retrieval order via interface from the on-site HOST. The goods are retrieved by the stacker cranes and transported via conveyor technology towards the shipping area. There are different loading areas for truck rear loading and truck side loading.

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