Reference DS Smith
Automated high-bay warehouse for corrugated board at DS Smith in France
HÖRMANN Intralogistics implements an automated high-bay warehouse for the careful storage of unpalletized and unsecured corrugated board formats for the packaging manufacturer DS Smith in France.
With innovation and commitment, the British company pursues its goal of being a leader in sustainable packaging. Around 30,000 employees work for DS Smith in 30 countries. At the French location in Durtal on the Loire River, a new two-aisle high-bay warehouse for corrugated sheetboards is being built. The project was planned and realized by HÖRMANN Intralogistics. The commissioning took place in the summer of 2022.
Concept
The high-bay warehouse (HRL) was built in a new hall next to the production hall. Via conveyor technology, the corrugated board stacks reach the pre-zone of the HRL. There, HÖRMANN Intralogistics takes over the stacks and transports them first through a contour check and then towards the SRM transfer. The conveyor system is designed so that 11 forks of the stacker crane can enter the conveyor system to pick up or deliver the load unit.
Gentle handling of corrugated stacks without strapping and without bottom plate
With decades of corrugated cardboard experience, HÖRMANN Intralogistics designed the new high-bay warehouse for DS Smith tailor-made to meet the requirements of the sensitive material and the different corrugated cardboard formats. Thus, the corrugated board stacks were divided into different width classes from 580 to 2620 mm. This allows them to be arranged in singles, pairs or triples. The two storage and retrieval machines (SRM) are each equipped with 11 individually motorized telescopic forks. Depending on the width category, a corresponding number of forks take up the stacks to transport and store them safely and gently.
The RBG can carry singles, pairs or triples units. In the rack compartments, several longitudinally aligned steel profiles ensure flexible use of space with different stacking widths with optimal, careful support of the format stacks. The compartments are precisely positioned using a camera-based compartment fine-positioning system. The volume-optimized occupancy of the compartments controls the warehouse management system HiLIS, which communicates with the customer system via an interface.
Facts
The scope of supply of HÖRMANN Intralogistics includes rack steel construction, stacker cranes, conveyor technology, the HiLIS WMS as well as the PLC-based plant control including plant visualization.
- High bay warehouse, 2-aisle
- 2 two-mast stacker cranes, each with 11 individually motorized telescopic forks
- Dimensions HRL 45 x 18 x 19 m (L x W x H)
- Storage capacity for approx. 630,000 m² corrugated sheetboards
- Inbound and outbound storage capacity each at least 61 units/h - operating hours 24/6
Food e-commerce warehousing
Fresh & fast - chilled & ambient storage and picking systems for e-grocery
Innovative e-grocery solutions for efficient storage and picking, especially for chilled and non-chilled products, are in high demand due to the rapid growth of online grocery. HÖRMANN Intralogistics specializes in the development of customized material handling systems that integrate high-bay storage, small parts storage (AutoStore), conveyor technology and warehouse management to meet hygiene and temperature requirements. We guarantee a comprehensive solution, from design to support, and serve as an overall reliable partner in the changing e-grocery sector.
Under the term e-grocery - or online supermarket - all online purchases are summarized, which belong to the goods of the classic food trade. This includes both food and non-food items. A particular challenge is the parallel storage and picking of refrigerated and non-refrigerated goods. E-grocery has achieved high growth rates in recent years, accelerated by the pandemic, and is expected to reach a market share of about 30% in 2030, according to forecasts.
For e-grocery fulfillment center operators, fast and cost-efficient picking plays a crucial role, because the final order phase from the e-grocery provider to the customer accounts for a significant share of total costs. In addition, the e-grocery idea thrives on easy click shopping and prompt delivery to the door. To meet these factors, automation of warehousing and picking processes is required.
Advantages of e-grocery solutions from HÖRMANN Intralogistics
- Over 35 years of intralogistics know-how
- Renowned food references and realization examples
- We assemble and combine custom solutions, selecting from our extensive portfolio
- Hardware and software from a single source
- Single point of contact for the entire project timeline, from conception to commissioning
- Lifecycle Support 24/7
Combined refrigeration and room temperature e-grocery micro-fulfillment solution for flaschenpost
The online supermarket flaschenpost went online with its instant delivery service in 2016 and today delivers food, beverages and everyday products to more than 200 cities in Germany. Over 20,000 employees currently ensure that the promise of "delivery within 120 minutes" is fulfilled from over 30 warehouse locations. At the location in Langenfeld (Rhineland), HÖRMANN Intralogistics for the first time built a micro-fulfillment solution with two combined AutoStore® systems, connecting conveyor technology as well as the necessary cooling system in an existing property.
Refrigerated and non-refrigerated goods with up to 9,500 container tenders per day
For the innovative design of the AutoStore® system, the different temperature zones "ambient" and "chilled" were combined in the planning of HÖRMANN Intralogistics in order to pick dry and chilled goods from both systems for one order.
The scope of supply includes the complete enclosure of the chilled system as well as the cooling technology to operate the system at 2°C. A specially adapted cooling system ensures minimal leakage during operation and optimal energy efficiency.
In its current configuration, the system is calculated for circa 1.000 container tenders per hour, but offers further growth possibilities in performance and storage space capacity. Approx. 100 m of connecting bin conveyor technology is installed for the delivery and removal of empty or order bins at the picking stations. This results in up to 12,000 articles per day which are handed over to the flaschenpost delivery drivers.
In the meantime, HÖRMANN Intralogistics has already received the order for a second micro-fulfillment project at a new logistics location of the online delivery service.
Facts
| AutoStore® "Chilled" | Autostore "Ambient" |
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AutoStore® system for refrigerated goods
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AutoStore® system for dry goods
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Cooled cheese specialties in new AutoStore® system boasting multi-order picking and connecting conveyor technology at Heiderbeck
Heiderbeck GmbH in Olching, Bavaria, is a successful distribution company in the German market for high-quality cheese specialties and refrigerated delicatessen products. For the storage of cheese specialties, HÖRMANN Intralogistics has built an AutoStore® system with the customized warehouse management system HiLIS AS and multi-order picking stations in an existing, cooled warehouse and expanded it during a consecutive expansion project.
At the five multi-order picking ports, employees pick specialty cheeses from the AutoStore® source containers, then follow the put-to-light displays, place them in up to four end customer shipping containers, and finally enter a receipt of the picking process directly into the put-to-light system. Stationary barcode scanners and destination bin locations with integrated rollers facilitate multi-order picking at the picking stations.
The shipping containers reach the palletization in the neighboring hall via the conveyor system, which was also built by HÖRMANN Intralogistics. To meet the food requirements, the AutoStore containers are constantly cleaned via two transfer cells.
The omniscient HÖRMANN Intralogistics Warehouse Management System HiLIS AS is directly connected to the customer HOST. It manages the AutoStore® warehouse and controls put-to-light picking orders as well as container management via transfer cells. The HiLIS AS visualization function enables staff to access all plant data and events at a glance.
Facts
| autostore system | material flow | ||
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Referenzvideo AutoStore bei Heiderbeck
HÖRMANN Intralogistics offers ideal cutting-edge material flow solution for the growing e-grocery market, as well as for food and non-food online suppliers.
Analyze your material flow with us & get a solution recommendation now!
Are you reaching the limits of your manual warehouse in terms of space and personnel requirements? We take a look at your actual and target situation and find a solution. Feel free to contact us for quotes free of cost.
Small Talk with Pawel Lusiak
Small Talk with Pawel Lusiak
HÖRMANN Intralogistics expanded to Eastern Europe with the establishment of HÖRMANN Intralogistics Polska. We chatted with Paweł Łusiak, Sales Manager in Gdansk about his story, tasks and outlook.
HÖRMANN Intralogistics (HI): Pawel, thank you very much for your time. You have many years of industry experience in automation technology, how did you get into the logistics industry and now also to HL?
Paweł Łusiak (PL): Thank you for asking, I remember my childhood, when all the other children dreamed of becoming a firefighter or pilot, I knew that I wanted to become an engineer. I've always been interested in civil engineering and architecture until I found out what control engineering is all about. So I worked hard to get to a good university, graduate from it and get my first job. I have been working for a company for over 8 years where I have learned a lot. First as an engineer, then as a team leader, and finally as a project manager. My dream came true, I worked for the biggest players in the automotive industry right from the start. When I decided to change my job 2 years ago, I switched to BDZ-Automation, where I was able to gather my first experiences in sales. In BDZ I realized that not only automotive industry has a lot to offer on the market but there is also a big market of intralogistics companies. As a sales manager, I discovered AutoStore and I wanted to market it.
HI: What do you particularly like about your work?
PL: In addition to traveling, I enjoy attracting new customers and understanding their needs. Every single customer is different and has his own ideas. It is a great feeling to sit down to the challenges and to meet the high demands. In this regard we agree with the HÖRMANN Intralogistics. It is an honour for us to be one of HÖRMANN Intralogistics´first partners on the Eastern European market.
HI: In your opinion, what makes HÖRMANN Intralogistics so important and how do you see the future of HÖRMANN Intralogistics Polska?
PL: My first impression is that the Hoermann Intralogistics team consists of passionate and experienced employees and a large number of projects and references speak for themselves. I am looking forward to working with a helpful and open team, as I get to know HÖRMANN Intralogistics. The Polish market is a growing market with a lot of potential for intralogistics solutions. Foreign companies invest in Poland due to its strategic location, well-trained managers and hard-working people. I am sure that we have the potential to inspire and overwhelm Polish customers for the future of automatic warehouses.
HI: What arguments would you use to attract new customers in Poland?
PL: We are a team of experienced employees and we know how to attract customers. In our daily task, we are more solution-oriented than problem-focused. We not only sell products, but with the support of HÖRMANN Intralogistics and BDZ-Automation we are able to support Polish customers.
HI: In which industries do you see potential in Poland?
PL: I would put e-commerce first. The Polish e-commerce market is still quite young and in many cases not as automated as in Germany. Intralogistics reports clearly show that Poland is one of the fastest growing markets in Europe. Every year we have new companies on the market as well as existing ones looking for modern solutions for their storage systems. E-commerce is rapidly replacing traditional shopping, which is also leading to a growing new sector in Poland based on fulfillment centers. For the reasons already mentioned, Poland is also interesting for companies if they want to start their business in Europe or be more cost-effective.
HI: Thank you very much and good luck!
Innovative multi-solution material flow solutions
Smart integrated warehousing
With individual, creative multi-solution intralogistics systems, we implement efficient and future-proof material flow solutions for various industries. We design and combine automated high-bay warehouses, tray and small parts/light goods warehouses, AutoStore® systems and picking systems specifically for your requirements to ensure maximum productivity for our customers.
Depending on the industry, volume, product characteristics, range, logistics property and required throughput, we can recommend and install the right autonomous solution for you. As a general contractor, we bear overall responsibility for implementation and are at your side with a single point of contact from planning to commissioning.
The overall system is integrated with HiLIS, our modular warehouse management system. HiLIS manages, controls and monitors all material flow processes online and ensures maximum transparency and system availability in all functional areas. Energy optimization with HiLIS Eco-Powermanagement.
The advantages of multi-solution intralogistics systems
- Increased storage capacity and throughput with one overall system through automation - even with different product groups
- Digitalization and acceleration of processes
- Compensating for the shortage of skilled workers
- Just-in-time and just-in-sequence supply of production and order picking
- Consolidation of different warehouses, goods sizes and handling speeds at a few space-saving, ergonomic picking workstations
- A warehouse management system for the entire material flow including Kanban material replenishment
Multi-solution project comprising an automated high-bay warehouse and AutoStore System® for the new logistics center at iDM Energiesysteme GmbH in Matrei
The iDM Group is Austria's largest manufacturer of heating heat pumps. Over 400 employees develop, produce and sell over 10,000 heat pumps for heating, cooling and hot water every year. iDM has made a name for itself with its development expertise and numerous innovations.
The intelligent iDM energy manager "Navigator 2.0" controls the heat pump, uses weather forecasts to adjust heat demand and solar power yields, learns the heating and cooling behaviour of individual rooms and optimizes running times by calling up electricity prices on an hourly basis. In this way, iDM makes a significant contribution to the energy transition with efficient and clean heat for generations.
Facts
| AutoStore® warehouse | High-bay warehouse |
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iDM Energiesysteme GmbH | Matrei, Tyrol | Reference film
Large and small parts handling with HRL, AGV, production connection and AutoStore® system at HASCO
In 85 years, HASCO Hasenclever GmbH und Co. KG has developed from a craft business into a globally successful industrial company that supplies high-precision products for tool and mold making. To keep pace with this growth, they commissioned HÖRMANN Intralogistics to build a high-bay warehouse in Lüdenscheid in 2012, followed by the addition of an AutoStore® system in 2022.
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The delivered raw panels are transported from the incoming goods area to the cutting line. An AGV driverless transport system distributes the pre-cut panels, which are placed on HASCO pallets, between cutting, high-bay warehouse, processing and dispatch.
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At the high-bay warehouse, the pallets, stacked up to 3 high, are transferred from the AGV to the conveyor, unstacked and transferred to the storage and retrieval machine (SRM) for storage. During pallet retrieval, the pallets are automatically stacked again and transported via the AGV either for processing or shipping.
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For the small parts, the dynamic AutoStore® system was subsequently installed at HASCO. Up to 144 storage and 720 retrieval operations per hour can be carried out at four Carousel workstations.
- Warehouse management and control for the entire handling of large and small parts is handled by the tried-and-tested HÖRMANN Intralogistics Warehouse Management System HiLIS, which communicates with the on-site HOST via an SAP interface.
Facts
| AutoStore® warehouse | High-bay warehouse |
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Fully automated multi-solution storage system at heat pump manufacturer Hoval spol. s r.o. in Slovakia
The renowned international heat pump supplier Hoval spol. s r.o. is increasing its capacities due to high demand with a fully automated storage system consisting of a pallet high-bay warehouse, conveyor technology and AutoStore® small parts warehouse. HÖRMANN Intralogistics was able to convince with its concept and is implementing the system in Slovakia as general contractor.
The plant in Istebnè, SK follows two current trends: On the one hand, HÖRMANN Intralogistics has already received its third order in the trend sector of heat pumps, which is experiencing an enormous upswing due to climate change and environmental protection targets. Secondly, fully automated multi-solution systems are increasingly being built in order to further optimize the degree of automation.
The storage system combines two different systems for large and small parts intralogistics. The centerpiece is a three-aisle pallet high-bay warehouse in silo design.
An Autostore® system is being built parallel to the high-bay warehouse. This offers space for 3,000 containers. The material flow of the complex multi-solution solution is controlled and monitored by the HiLIS Warehouse Management System, which synchronizes the two automated storage areas and optimizes material flows for combined picking workstations.
Facts
| Pallet- High-bay warehouse |
AutoStore® warehouse |
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Analyze your material flow now & get a solution recommendation!
Are you reaching the limits of your manual warehouse in terms of space and personnel requirements? We will take a look at your current and target situation and find a solution. Please feel free to contact us without obligation.