Kardex Mlog Revamps Logistics for Salt Works in Bad Reichenhall

After nearly 40 years of operation and countless in- and out-loading in salty air, all three stacker cranes (RBGs) of a high-bay warehouse of Südwestdeutsche Salzwerke AG (SWS AG) at the Bad Reichenhall site had to be replaced. The availability of the salt warehouse, which operates in two shifts, could no longer be guaranteed. In close cooperation with logistics consultant Bernhard Lechner, the choice fell on Kardex Mlog.

(Neuenstadt/Bad Reichenhall) In the first step, the Kardex Mlog team dismantled the existing equipment and the gas equipment. The old RBGs were removed with the help of a crane through a roof hatch. The three new devices of type MSingle A 1100, whose corrosion protection far exceeds the usual standard, took the same route in the opposite direction. During production in Neuenstadt, all galvanized parts were painted or powder-coated. The screws required for adjustments and settings are made of stainless V2A steel. All other screws were painted over. The guide rail was also painted in areas outside the running surface.

Although the original RBGs came from a competitor, Kardex Mlog had proven to be a reliable project partner during the construction of another high-bay warehouse at the Reichenhall site. August 2021 was chosen as the project period. For the approximately four-week conversion phase, the goods packed on Euro and plastic pallets were stored in an external warehouse.

Longer Lifespan

The maintenance-friendly technology of the MSingle A allows for a cost-effective automation variant while achieving high throughput and maximum space utilization. The devices supplied for SWS AG are 22.8 m high and offer a load capacity of 1,000 kg. Due to the compact pipe mast construction and the omission of a closed operator’s cabin, the MSingle A scores with a lower dead weight compared to conventional RBGs. This allows for smaller drives to be used for both the chassis and the lifting mechanism, saving energy. The slim design also allows for a narrower aisle width and very small approach dimensions in the chassis and lifting directions. Another design feature is the rope deflection at the column head: This is done via two roller-mounted plastic rope pulleys, which enables a longer lifespan of the lifting rope.

The in- and out-loading orders are transmitted to the machines via the warehouse management computer (LVR). The necessary data interfaces were set up by Kardex Mlog. The lift trucks are equipped with a telescopic fork for single-depth storage with two tines. Each RBG accelerates to a maximum of 100 m/min for travel and 60 m/min for lifting movements, achieving around 35 double cycles per hour. This corresponds to a performance of over 100 in- and out-loadings throughout the warehouse. “We have increased the performance of the warehouse by about 33 percent,” states Kardex Mlog project manager Sebastian Haist.

Conversion in Just Under Four Weeks

The first of three MSingle A 1100 units was already put into operation on August 18, 2021. The other two RBGs followed just a few days later, allowing the entire conversion phase, including connection to the warehouse management system, to be limited to just under four weeks. “We are more than satisfied with the project progress. The team from Kardex Mlog worked quickly and professionally and kept us informed at every step,” explains the project manager of Südwestdeutsche Salzwerke AG.

Each RBG is equipped with a mounted control cabinet that features a touch panel. This allows the stacker crane to be operated in semi-automatic, manual, and setup modes. Modern controls of the type Siemens S7-1500F and SEW Movi PLC ensure the execution of travel and lift commands. Any errors or malfunctions during operation can be easily and quickly localized with the help of the cameras installed on the RBGs. The camera’s field of view is illuminated for better image representation.

Maintenance Without Access to the Aisle

In conjunction with the visualization system MVisu, many malfunctions can be resolved remotely without accessing the aisle. MVisu is a module of the Mlog Control Center (MCC). With MVisu, the entire automatic conveyor systems and stacker cranes, as well as their operating states, can be graphically displayed.

Photo: © Kardex Mlog