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It was a matter of millimeters: With the help of a 60-meter-high heavy-duty crane, the first of a total of 61 new stacker cranes has been installed today in the high-bay warehouse of Hermes Fulfilment in Haldensleben. Through an opening of about ten square meters in the roof, the approximately twelve-ton and 27-meter-high colossus made of steel was lifted into the hall in two parts.
(Hamburg/Haldensleben) Hermes Fulfilment is investing a mid double-digit million amount in the new technology. The gradual replacement of the stacker cranes, or RBG for short, is expected to be completed by the end of 2028.
Since 1994, the location has been a logistical hub for trading companies of the Otto Group. The Haldensleben shipping center specializes in handling small-volume assortments, primarily clothing and shoes. With state-of-the-art technology, robotics, and AI, Hermes Fulfilment manages warehousing, packs parcels and bags with items ordered online, takes care of shipping to more than 20 European countries, and re-stores items returned due to dissatisfaction.
The Heart of the Operation is the High-Bay Warehouse
The centerpiece of the facility on Hamburger Straße is the high-bay warehouse. The 27-meter-high shelves on the left and right of the 61 narrow aisles have space for 1.2 million cartons of new goods. These are automatically stored and retrieved using stacker cranes. A large part of this heavy-duty technology is now 31 years old and has already completed millions of trips. The consequence: material fatigue. “The risk of failure is increasing. Electronic spare parts are no longer available for long. To ensure we can continue using the high-bay warehouse in the future, we have decided to completely replace the RBG in a total of nine construction phases. The TÜV also advised us to make replacement investments after on-site inspections,” explains Barbara Schröder. She works in logistics planning at Hermes Fulfilment and leads the project “Goliath 61,” named after the size and number of the new stacker cranes.
So far, 39 RBGs are in use, which can switch aisles with the help of eight movers. In the future, each of the 61 aisles will be served by one device each. The switching will be eliminated. “That saves time,” says Barbara Schröder. Furthermore, the new stacker cranes from the Swiss manufacturer Stöcklin will be significantly more agile and powerful. They are four tons lighter than their predecessors and move through the shelves at a speed of four meters per second, making them faster. Although the new RBGs can only transport three instead of 15 cartons at a time, the overall performance of the high-bay warehouse will increase from 3,500 to even 3,900 storage and retrieval operations per hour due to the higher number of devices and the speed and weight advantages. “This keeps the location fit for the online trade of tomorrow,” emphasizes Barbara Schröder.
Renewal in Every Aisle
In the first quarter of this year, the material flow computer was replaced as part of the Goliath 61 project. The manufacturer TUP programmed the software so that it can control both the old and new RBGs until the last stacker cranes are installed by the end of 2028. For the new devices to take over and hand over the cartons fully automatically, conveyor technology must be expanded and connected to the existing technology in each aisle. All modernization steps will take place during ongoing operations in the existing system: “This requires the highest level of coordination and precision from all parties involved and makes the entire project a real challenge,” emphasizes Barbara Schröder. After the pilot RBG, the next replacement is scheduled for the second quarter of 2026. Then, another four stacker cranes are to be installed and removed. The old steel colossi will be scrapped, except for still usable components.
For Stefan Nießen, head of the shipping center on Hamburger Straße, the Goliath 61 project fits into the modernization measures of recent years: “By replacing the stacker cranes, we are continuing to invest in the future of the location and sending a powerful signal: Haldensleben will continue to be a beacon of logistics within the Otto Group.”
About 4,000 Employees
Around 4,000 employees work at Hermes Fulfilment in Haldensleben. This makes the company the largest employer in the city and one of the ten largest employers in the country.
Photo: ©
