Temperature-controlled high-bay warehouse for dairy products

Milchwerke Berchtesgadener Land in Piding

Milchwerke Berchtesgadener Land Chiemgau eG is owned by the region's approximately 1,700 organic and mountain farmers. Around the clock, the 480 employees in Piding produce dairy products exclusively from fresh milk from member farms. In addition to the conventional food trade and the natural food trade, the catering and hotel trade are also among the customers. In order to cope with the growing production volumes, a third fully automated high-bay warehouse (HRL) was built in Piding, which is connected to production and the two existing warehouses via a conveyor bridge.

The project included the new building with steel rack construction, roof / wall cladding, bridge, stacker cranes (RBG), sprinkler system, EHB, conveyor technology, fire protection and high-speed doors, winder and labeler, as well as the control and warehouse management software with visualization.

Concept

The new six-aisle HRL is divided into two temperature zones (4 °C and 15 °C). A thermal partition separates the four refrigerated aisles from the two hot aisles. Attached to the new building is the new picking and shipping area. The goods are palletized on Euro pallets in the production area and recorded in the data system. It is transported via pallet conveyor technology to an electric monorail system (EMS), which was modified in some places in the existing plant and completely reinstalled in the new building with 50 vehicles.

A new functional building was built adjacent to the new HRL, in which four floors are connected via vertical conveyors, conveyor technology and EHB. In the HRL, the goods are stored in the designated temperature zone by six highly dynamic storage and retrieval machines (SRMs). These stacker cranes are equipped with image-processing compartment fine positioning and save up to 25% of energy consumption thanks to the HiLIS Eco power management system. A major challenge was the required retrieval rate of around 200 pallets per hour, which can only be achieved with intelligent control mechanisms.

With the EHB, goods are retrieved from all storage areas. The ability to resequence ensures that they are provided to the shipping lanes exactly in the required sequence. Visually, too, the new HRL is an absolute highlight in the region thanks to its artistic facade design by Christian Hundertmark.

Highlights

• 6-aisle high-bay warehouse: 65 x 45 x 28 m (L x W x H)
• Silo construction with 2-fold deep storage and production connection
• 10,700 pallet spaces for dairy products and RHB materials
• Input and retrieval capacity approx. 200 SU/hour
• Two temperature ranges 4 °C/15°C, separated by a thermal wall
• Automatic interlinking of the areas of production, pallet inspection, goods receipt, picking, sorting, shipping provision and existing high-bay storage
• Connection to inventory by means of EHB bridge
• Electric monorail with 610 m of track, 59 vehicles, 16 switches
• Installation and commissioning of the new building without interfering with ongoing operations
• Installation of an overall warehouse management software

Center of Cheese Competence SalzburgMilch

SalzburgMilch GmbH is Salzburg's most important dairy and is majority-owned by three cooperatives. Just under 42% is held by the Meggle dairy in Wasserburg. The company wants to actively contribute to safeguarding rural structures and regionally refined, high-quality dairy products.

A modern Cheese Competence Center (KKC) was built at the Lamprechtshausen site, which, with total costs of 45 million euros, is the largest and most important investment in the company's history to date. HÖRMANN Logistik was awarded the contract for the realization of a high-bay warehouse (HRL) integrated in the KKC. The scope of the order included storage and retrieval machines and conveyor systems, each with control technology, as well as the comprehensive warehouse management system.

Concept

The three-aisle HRL is divided into two temperature zones (15 °C and 4 °C). One aisle is designed as a hot storage area for storing raw materials, consumables and supplies, while the other two aisles are designed as cold storage areas for storing finished products. The goods to be stored are either supplied to the HRL as merchandise from incoming goods or they arrive from production on different loading units, such as Euro, Chep or one-way pallets. A highly dynamic distribution car connects the areas of storage, high-bay warehouse, order picking and shipping.

Three automatic storage and retrieval machines (SRMs) pick up the load units via telescopic forks and store them two-deep in the high-bay warehouse. Depending on the customer order, the goods are retrieved tour-specifically and according to predefined quality characteristics (e.g., minimum shelf life) and either made available for picking or directly to the shipping lanes in the goods issue area. SalzburgMilch's RBGs also work with the HiLIS Eco-Powermanagement System and thus achieve high energy savings. In the cheese dairy warehouse, transfer orders are generated automatically as needed. The warehouse management system plays a central role in the new system.

In addition to master data management, best-before date management, and batch traceability, the WMS also controls the storage and retrieval processes, timely supply to the picking department, provision of goods at goods issue, and all processes in the separate cheese dairy warehouse. This is divided into different ripening zones, which are managed area-specifically according to the stored ripening step chain, whereby, for example, transfer orders for ripening containers are generated automatically if required.

Highlights

• 3-aisle high-bay warehouse: 53 x 23 x 26 m (L x W x H)
• Silo construction with 2-fold deep storage
• 5,300 pallet spaces
• Two temperature ranges with 4 °C / 15 °C, separated by a theme partition
• Automatic interlinking of the production, goods receipt, picking, dispatch preparation areas
• Warehouse management software

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