Kardex Mlog Realizes Fourth High-Rack Warehouse for Dairy Gropper

Dairy Gropper has expanded its fully automated central warehouse at its headquarters in Bissingen with Kardex Mlog by adding a fourth high-rack warehouse, thereby creating space for an additional 5,177 pallets. The construction of the facility and its integration into the existing conveyor technology during ongoing operations posed a challenge for Kardex Mlog, which was able to establish itself as a new and reliable supplier for Gropper.

(Neustadt) A maximum of 48 hours between order and delivery: This promise is fulfilled by the Swabian dairy Gropper with efficient production and rational logistics. More than 60 employees pick and load the refrigerated products around the clock, with a large part of the processes being automated.

In 2017, the storage and shipping capacities used in three-shift operation had once again reached their limits. Just in 2014, the company headquarters had been expanded with a third high-rack warehouse (HRL3), which was connected to the other storage areas via a bridge approximately 25m long. There is also a connection to the directly adjacent production and shipping building, which was also built in 2014. The new task was to build a fourth high-rack warehouse with four storage aisles directly next to HRL3 and to integrate the associated conveyor technology into the existing structures.

Experience Has Convincingly

In the course of the tender for the approximately 6 million EUR project, Gropper chose Kardex Mlog, even though the existing facility was built by other suppliers. In addition to a good price-performance ratio, the intralogistics specialists convinced with components developed and manufactured in Germany as well as their extensive experience in the conversion of industrial plants during ongoing operations. “The new high-rack warehouse HRL4 had to be connected to the goods receipt, HRL3, and shipping without affecting production,” reports Andreas Koch, who works in sales at Kardex Mlog and has accompanied the entire project.

The HRL4 planned and built by Kardex Mlog is 28.4 m high and allows storage on up to 11 levels. On a footprint of 64.5 x 23.6 m, four storage aisles were realized, in which double-deep storage and retrieval takes place. For this purpose, storage and retrieval machines (RBG) of type MSingle B are used, which can enable up to 37 double cycles per hour depending on the case consideration. This results in a total performance of up to 140 pallets per hour. Their storage and retrieval processes are monitored by a camera system that transmits images to an Ethernet network. The last images before a potential disturbance are stored.

25 Percent More Efficient

Each RBG is 26m high and picks up pallets weighing up to 1,000 kilograms via a telescopic fork. The transport takes place at a speed of 140 m/min. The regulated ambient temperature of the cold storage ranges between +2 and +7 degrees Celsius, with one of the aisles also being operated at +10 to +15 degrees. The RBGs are equipped with a circuit coupling, which allows the generated energy of one axis to be used for other axes. Additionally, the control of the drive and lifting systems is optimized so that the movement axes can be started and decelerated precisely. “This makes the storage and retrieval machines operate up to 25 percent more efficiently,” emphasizes Koch.

Critical project steps included connecting the new high-rack warehouse to HRL3 and production. For this purpose, various modifications were necessary, which could only be carried out on weekends, considering production. The plan included a new conveyor line between HRL3 and HRL4 as well as modernizing and expanding existing elements and components. A total of 137 conveyor technology drives were required for the new facility. In addition, 34 drives were installed as part of the conversion.

Conversion on Weekends

The transition between the existing and the new high-rack warehouse was realized through a lock with a high-speed door. For its installation, the outer facade of HRL3 had to be opened, and the drive of a roller conveyor had to be modified, which took two weekends. The modifications in the area of the bridge between HRL2 and HRL3 took another four weekends. During this time, two chain conveyors were replaced, among other things. Additionally, four new roller conveyor elements, four high-speed doors, and an enclosure were integrated into the material flow.

The conveyor lines in the area of the pallet wrappers, which are now also controlled by HRL4, also needed to be expanded. The installation of additional lifting tables, roller and chain conveyors, as well as the replacement of existing conveyor elements with turntables was completed within five weekends. Another conveyor technology line was laid from HRL4 towards the shipping area in the adjacent production building and connected to the existing material flow with the help of a new turntable. Up to seven trucks are stationed at the loading docks there, which must be processed in the shortest possible time.

Extensive Training

In April 2018 – just under 12 months after the order was awarded – Kardex Mlog was able to complete the demanding expansion project on time. This was rounded off with extensive training measures for the employees to enable a smooth and independent operation from the very beginning. Conclusion: Kardex Mlog has proven itself as a new supplier for intralogistics at Dairy Gropper. “The trust placed in Kardex Mlog regarding competence and reliability has been confirmed. We are very satisfied with the entire project execution,” confirms Karl Klein, managing director of Dairy Gropper GmbH & Co. KG.

Photo: © Kardex Mlog