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26, Issue 2/2015

Company magazine
Cover story Automotive

Food industry

Logistics service providers

Brose Group:
Innovative tugger train solution
eliminates need for forklifts

Vietnams high-tech dairy
distribution centre

Khne + Nagel:
Innovative combination
of systems



Dear readers,
We are committed to helping our customers maintain
their competitive edge in the global marketplace. Increasing throughput, streamlining material flows and
ensuring reliable processes while reducing error rates
to almost zero these are just a few of the objectives
companies across multiple industries approach us
with. To help them achieve their goals, we implement
both manual warehousing systems and fully automated, turnkey distribution centres.
Intralogistics has developed into a high-tech industry,
with automated warehouse and logistics processes,
and purpose-designed software. The technologies we
deploy in our projects reflect this trend: they include
high-throughput warehouses and storage systems, efficient picking solutions, fully automated storage and retrieval machines, sophisticated robotics, intelligent inventory data capture methods, and reliable warehouse
management software. Our automotive-themed cover
story on the Brose Group spotlights many of these solutions in action.

Harrie Swinkels
Managing Director, SSI Schaefer, Giebelstadt, Germany

SSI Schaefers warehousing and logistics systems

are at the cutting edge of developments we have a
tradition of innovation. Against this background, I am
pleased to introduce our new product, Navette, in this
issue of Update. Our scalable, multi-level shuttle can
move up to four totes, trays, or cartons at a time, by
means of its two load-handling devices. As a result, it
shortens travel time while doubling process efficiency.
The special feature article describes our Customer
Service and Support division, which offers new and established customers a broad portfolio of services. In
particular, we address the growing demand for upgrading and retrofitting. Within the scope of these projects,
we focus on designing solutions tailored to our customers specific needs helping them create high-availability storage and maximise their productivity.
Read on to learn more about the exciting world of intralogistics at SSI Schaefer. We hope you enjoy.







Cover story Brose Group:

Innovative tugger train solution
eliminates need for forklifts
Project BMW Vogl/Total/Carglass



Project Liebherr-Aerospace/Lely/
Glenbeigh/Belimo Americas/



Food industry

Logistics service providers


Special feature

Solution Made-to-measure customer

service and support
Project A. Kempf/Oriflame





Project Khne + Nagel

Inside SSI Schaefer

Interview Growing demand for upgrades

Product Navette the scalable,
multi-level shuttle
News Production plant expansion
in Asia

Project Dafgrd/Nila Sea Foods/


Cover story Automotive

Innovative tugger train solution

eliminates need for forklifts
Brose Group, the worlds fifth largest family-owned automotive supplier, called on SSI Schaefers proven expertise when constructing
its new logistics centre in the Czech city of Ostrava. The one-stop
solutions provider created innovative material flows managed by
using a SAP EWM solution tailored precisely to the customers
needs to supply the highly dynamic parts to Broses production line.

Each of the four tugger train stations has

a racking system comprising four levels and
a total of 32 tote channels. A train with four
trailers arrives at the
station where loading is
due to take place.

Cover story Automotive

Kopivnice, Czech Republic. SSI Schaefer has

constructed a new logistics centre at Broses
manufacturing site in Kopivnice, near the Czech
city of Ostrava. By consolidating storage capacity
inside the plant, the Brose Group aimed to cut
shipment and external storage costs, streamline
material flows, optimise production line supply
processes and boost throughput.
To achieve these goals, SSI Schaefer deployed
a highly automated logistics solution. First,
SSI Schaefer constructed a five-aisle high-bay
warehouse with 9,750 pallet positions in a singledeep configuration, with the goal of increasing
capacity and streamlining intralogistics. Five Exyz
storage and retrieval systems ensure maximum
energy efficiency during picking and putaway. A
travel speed of 180 metres per minute and lifting
speed of 48 metres per minute enable throughput
of 200 pallets per hour. The warehouse provides
storage for reserve stock, and is connected to an
existing building via a bridge. It houses the goods
receipt area, the conveyor systems and processing points, plus an automated small parts
Brose opted to pursue the goal of a forklift-free
logistics facility. With this in mind, tugger trains
are used to supply parts to the production line.
All intralogistics processes are fully automated,
including loading. The seven-aisle small parts
warehouse can store up to 23,520 totes, each
weighing up to 15 kilogrammes, in either singledeep or double-deep configurations. Seven storage and retrieval systems from the tried-andtrusted Schaefer Miniload Cranes (SMC 1) range
enable throughput of up to 840 totes per hour.
Totes supplying parts to the production line are
loaded at four tugger train stations, located on the
upstream sides of the automated small parts
warehouse. Once the train has reached the correct position, the totes are released, the locking
roller lowers, and the totes roll onto the trailer

technology, vertical conveyors and robotic arms

that fully automate the depalletising process ensures high material flow efficiency. Teaching the
robotic arms to perform their tasks was a particular challenge and to solve it, SSI Schaefer
combined state-of-the-art image recognition with
device control technology and SAP EMW.

Material flow at the logistics centre is also highly

innovative. SSI Schaefer has integrated a customised SAP EWM solution into the existing SAP infrastructure. As Jrgen Hergenrther, IT/SAP Project
Manager at SSI Schaefer, explains, SAP EWM
calculates where the tugger train needs to stop
on its journey, and plans the routes and locations
of trains, trailers and storage positions accordingly. It also organises and controls all underlying
processes to ensure loading and supply processes take place exactly when and where they are
needed. The combination of pallet conveying

As Claudia Vogel-Daniel, Project Manager at

Brose, says, The new solution has reduced the
need for manual input and optimised material
flow. Whats more, it has cut personnel costs
and enhanced ergonomics. By increasing plant
automation, redefining our material flows and
deploying an end-to-end SAP solution, we have
simplified, streamlined and increased visibility into our processes, and have boosted our
throughput, too. We are extremely pleased with
this intelligent solution, which has fully automated
the supply of parts to the production line.

The Schaefer Miniload

Cranes can collect up
to two totes, depending on the type of tote.
As a result, they enable throughput of up
to 840 totes per hour.


BMW Vogls new

storage system
doubles the speed
of wheel putaway
and picking.

An intelligent combination of technologies

boosts efficiency
An innovative wheel and parts storage system has created
structured, accelerated processes, saved considerable space,
and greatly improved ergonomics at BMW Vogl.
Mhldorf am Inn, Germany. Since 2001, BMW Vogl
has been one of Germanys top 20 BMW dealerships. In 2013, a new BMW and Mini centre was
opened in Mhldorf am Inn. Within the scope of
this project, BMW Vogl contracted SSI Schaefer to
implement a new warehouse, comprising fixed location and wheel and tyre storage systems, with
pallet dollies and stackers.

efficiency. This also improves working conditions,

as it eliminates the need for heavy lifting during
putaway and picking. The combination of dollies
and pallet stackers has proven highly successful.
Vertical movements are completed in just 18 seconds offering over 50 per cent greater time efficiency than conventional systems. Moreover, there
are practically no picking errors.

Developing a new wheel storage system was the

primary challenge; approximately 1,100 sets of
wheels have to be stored on 150 square metres.
Capacity and process efficiency were not the only
important factors ergonomics is also critical.
Our productivity goals shouldnt be achieved at
the cost of employees back pain, explains Bernd
Rupprecht, responsible for fixed location storage
sales at SSI Schaefer. A typical wheel weighs 20
to 25 kilogrammes; SUV wheels tip the scales at
35 kilogrammes. Handling these heavy items is
tough physical work, and places great strain on
employees backs.

Fixed location warehousing has been a mainstay

of the automotive industry for many years. It offers
a number of advantages: up to 50 per cent space
savings, shorter picking tours due to optimised
layouts, and an extremely low picking error rate,
as every part has an assigned position. BMW
Vogl stores approximately 4,500 spare parts on
R 3000 modular shelves on a two-level mezzanine,
taking up only 240 square metres of floor space.

Our new storage system enables us to provide our

customers with the high-quality service they have
come to expect from one of Germanys leading
BMW dealerships. It was a pleasure to work with
Sets of four wheels are stored double-deep, SSI Schaefer; we have formed an excellent partwith each pair occupying one storage position. nership, notes Jrgen Pllner, Managing Director
SSI Schaefer introduced pallet dollies to increase at BMW Vogl.

Efficient pallet
live storage

Loading and unloading

take place on opposite
sides of the pallet live
storage system.

Ertvelde, Belgium. Total supplies high-quality

petrol and diesel throughout Belgium via more
than 500 stations. But the company is also a
global player in the energy industry, with a broad
portfolio comprising fuel oil, LPG, renewables,
speciality chemicals, and more.
SSI Schaefer implemented a pallet live storage
system at Totals Ertvelde distribution centre in
north-eastern Belgium. The solution was installed
in the centres staging area, providing buffer storage prior to shipment. In addition, it serves as a
means of conveying pallets loaded with oil drums,
canisters, and cartons. The system consists of
12 aisles, three levels, and a single channel with
roller tracks and 10 pallet positions.
Loaded pallets which can weigh up to 1,000
kilogrammes each are transported on conveyor belts to the staging area, where forklifts place
them on the racking systems roller track. They
are unloaded by forklifts on the opposite side of
the racking meaning putaway and retrieval pro- cantly increased our capacity, creating 360 new
cesses remain independent.
pallet positions, states Peter Van Laere, Project
Leader at Total. The company has already drawn
Total is very satisfied with the system. up plans to replace the forklifts with automated
SSI Schaefer provided a solution that signifi- guided vehicles (AGVs).

Carglass enjoys accessible, practical storage

SSI Schaefer has implemented
shelving for car parts in Carglass
European distribution centre.

Hasselt, Belgium. Carglass has been Belgiums leading automotive

window specialist for over 25 years. The companys core competency is repair and replacement for all car makes, models, and ages.
They provide 24/7 customer service, using 41 workshops and a fleet
of 100 mobile technicians in Belgium. Moreover, Carglass provides a
lifetime guarantee on all workmanship, including the watertight seal on
replacement windscreens.
To perform repairs rapidly and reliably, Carglass needs a warehouse infrastructure of the highest standard. With this goal in mind,
SSI Schaefer equipped Carglass European distribution centre with
shelving for work clothing, and R 3000 modular shelving systems for
car components of a variety of types and brands supporting picking
processes for both fast and slow-moving items.
For greater efficiency, repair materials and accessories are stored in
Euro-Fix boxes on modular shelving systems on a mezzanine.

Low-turnover car parts for various models

and makes are picked daily from accessible, ergonomic storage.


Taking efficiency
to a new level
Within the scope of a large-scale
expansion of their production plant,
Liebherr-Aerospace Lindenberg has
built a new logistics centre. All
processes in this automated highefficiency warehouse are managed
with WAMAS software.

SSI Schaefers WAMAS software

supports the ongoing optimisation of all processes in the new
logistics hall in line with actual
needs, and uses graphics to
visualise current inventory.

Lindenberg, Germany. Liebherr-Aerospace, a

leading European manufacturer of aerospace
components, commenced a major expansion
project for their plant in Lindenberg, Germany,
in 2012. SSI Schaefer, Neunkirchen, was tasked
with implementing a new warehouse management solution to streamline the plants intralogistics processes.
The site posed a unique challenge: the new
racking systems needed to be installed in a
15,700-square-metre logistics hall and assembly area for flight control systems that were 20
metres below normal ground level. Werner Grund,
SSI Schaefers Project Leader explains, The
steep incline of the land is responsible for this
unusual situation. In other words, the floor of
these zones had to be lowered to maximise the
available surface area.

The three-aisle
high-rise racking
was installed on
a floor that had
been lowered by
20 metres.

Over the course of just a few months,

SSI Schaefer succeeded in building an automated high-bay racking system and an automated
small parts storage system. Both are connected
by conveyor systems to repacking and picking

stations that are at level 0 (i.e. 20 metres

above the lowered floors).
The three-aisle high-bay racking, in a single-deep
configuration, offers a total of 6,714 pallet positions. These are served by Exyz storage and
retrieval machines (SRMs) which put away and retrieve 39 pallets an hour, at an average speed of
220 metres per minute. Four single-mast Schaefer
Miniload Cranes (SMC, type 1) which each put
away and retrieve an average of 77.5 containers an
hour are deployed in the four-aisle, double-deep
small parts storage system comprising 63,440
container positions. Thanks to SSI Schaefers
Green Crane Technology, travel speed and acceleration can be aligned precisely with actual needs,
minimising both wear and electricity consumption.
The introduction of WAMAS logistics software has
also helped improve plant productivity. The solution supports the ongoing optimisation of all processes in the new logistics hall in line with actual
needs. WAMAS is deployed within a client/server
environment, and uses graphics to visualise current inventory. The software therefore offers an
at-a-glance overview of plant capacity utilisation,
and, in addition, enables rapid analysis and
It is clear to Markus Heinrich, Head of Logistics at
Liebherr-Aerospace Lindenberg, that they chose
the right partner to implement these improvements. He stated: We had a very good working
relationship with SSI Schaefer throughout the entire project they proved to be very skilled, professional and reliable. The changes have improved
the aerospace specialists ability to respond to
fluctuating market conditions within a highly competitive, international business environment.

Eco-friendly intralogistics
for Lelys new campus
Maassluis, the Netherlands. The Lely Group is an
acknowledged pioneer in the agricultural sector.
Its portfolio includes forage harvest machines,
automatic livestock feeding systems, mobile barn
cleaners, and robotic milking systems.
SSI Schaefer installed in-line shelving at 18 assembly stations on the high-tech production lines
at Lelys new innovation campus. This shelving
ensures that small parts are always easily accessible, and precisely where they need to be.
SSI Schaefer also provided a pallet racking system for Lelys warehouse, for storing materials
sold by the metre.
In the future, Lely will also deploy SSI Schaefer
LTB containers to reduce waste packaging generated during production, and to minimise the companys environmental footprint.

Pallet racking for

storing materials
sold by the metre.

Small parts and items available to rent are stored

on modular shelving on a mezzanine, increasing
efficiency. Previously, the shelves were distributed around the workshop. Now, everything is
centralised; we have saved space and have reduced picking time. Whats more, items are
stored in a much more structured way, explains
Peter Boere, Workshop Team Manager at Lely
Industries NV.
Lelys new campus was awarded five stars for
exceptional sustainability under the BREEAM certification program. The new, eco-friendly complex
was opened in January 2014 by Queen Mxima.

Storage capacity doubled

Dubai, United Arab Emirates. Glenbeigh Construction, a member of the Glenbeigh Group, is
one of Irelands leading construction companies,
with operations in the United Kingdom and the
United Arab Emirates. The enterprise was founded in 1985, and provides project management
with in-house design, response care teams, and
pre-engineered low carbon off-site building solutions, for both the private and public sectors.

of a significant number of cartons. The intralogistics expert implemented a multi-tier mezzanine system; the racks make full use of available
headroom, and can store one million cartons. By
leveraging vertical storage, SSI Schaefer eliminated the need for an increased footprint, and
doubled the warehouses capacity.

The multi-tier
mezzanine system
can store up to one
million cartons.

SSI Schaefers racking systems ensured that our

clients critical records are stored in a facility of
Recently, Gleinbeigh Construction built a ware- a high standard, and provide us with prompt achouse for its sister company Glenbeigh Records cess to records; this ensures that we meet our
Management. This new document management one-hour service-level delivery targets, explains
and archiving facility is located in the new aviation Declan Brady, Managing Director at Glenbeigh
and logistics hub at Dubai World Central.
Records Management.
SSI Schaefer was contracted to provide an efficient, secure and reliable solution for the storage


warehouse solution
for Belimo Americas
Accelerated picking improves
material flows and increases

The combination of manual

and automated warehouse systems greatly improves process
efficiency and saves time.

Connecticut, USA. SSI Schaefer has implemented a 7,000-square-metre automated warehouse for Belimo Americas, a manufacturer of
actuators and control valves.
The scope of services included automated small
parts storage with 16,320 tray and container
positions, container conveyor systems, a pallet
live storage system, narrow-aisle pallet racking,
SSI Schaefers WAMAS logistics software, and
goods-to-person workstations for picking, packing, and pre-assembly.
The conveyor system loop serves three picking
zones, including the narrow-aisle racking, the live
storage system, and the picking workstations,
where extremely fast-moving AA, fast-moving A,
and slow-moving B SKUs are stored, respectively. The goods are retrieved by Schaefer Miniload

Cranes (SMC), and are transported from the small

parts storage system via containers. The exceptionally low-noise conveyor system and highly ergonomic workstations help create a pleasant and
productive working environment.
Once items have been picked and placed in containers, they are sent to packing stations. If parts
require pre-assembly, they are conveyed to dedicated workstations before being prepared for
shipping. The decoupled workstations ensure process efficiency, and accelerate receiving-to-shipping time.
The project was delivered on time, and we were
able to transition into our new facility as per schedule without interruption to our business and customer service, explains John Coppola, Vice President
of Finance and Administration at Belimo Americas.

3D-MATRIX Solution for greater

efficiency and scalability
Haiger, Germany. Klingspor is a major player in abrasive technology, distributing over 200 metric tons of grinding wheels and similar materials to
80 countries daily. The enterprise has a portfolio of more than 50,000 products and as a result, requires highly efficient storage systems. Against this
background, Klingspor contracted SSI Schaefer with upgrading their existing
distribution centre, with a focus on ensuring timely delivery.

Design of Klingspors
pallet racking and
shuttle-served channel
storage systems.

At the production plant in Haiger, SSI Schaefer is installing a threeaisle, double-deep pallet racking system, with 13,400 positions, and a
shuttle-served channel storage system with 36,000 container positions. The new configuration will incorporate SSI Schaefers innovative 3D-MATRIX Solution which
provides outstanding efficiency, flexibility, redundancy and scalability.
Three energy-efficient Exyz storage and retrieval systems will streamline putaway and picking in the 2 x
120-channel pallet racking system. A pallet conveyor system with a programmable logic controller (PLC)
connects the 26-metre-high racking system to three picking stations and the receiving and shipping
areas. On the other side of the building, a Navette shuttle system comprising 21 Navette vehicles and
nine Navette lifts serves a 26-metre high channel storage system. This storage system is linked by
conveyors to four staging areas located in the extremely high-turnover AA SKU zone, and to four multiorder stations and eight packing stations. In addition, Klingspor plans to introduce SAP EMW (Extended
Warehouse Management) software, which will also be implemented by SSI Schaefer. The upgraded
warehouse is slated to commence operation in mid-2016 and will play a key role in the enterprises
future growth.



A tailor-made storage solution

A combination of SSI Schaefer racking components is shortening picking routes,
optimising material flow, and improving ergonomics in Schunks new warehouse.
Heuchelheim, Germany. Schunk products have
become indispensable across a variety of industries. They are used, for example, in cars, ships,
electronic devices, wind turbines, space shuttles,
medical technology, the solar power industry, and
LED lighting. To support its expanding portfolio of
products, the enterprise decided to increase its
efficiency and combine its warehouses for maintenance materials and equipment for water, gas,
and electric installations. Schunk contracted
SSI Schaefer to plan and execute the restructuring

an integrated receiving area and only speciallytrained warehouse staff may enter. Their task is to
handle more complex requests from electricians,
to pick and put away components, and to plan
inventory (including placing orders for corresponding products). SSI Schaefer equipped the parts
issuing desk with drawer shelving.

A track-free mobile racking system with R 3000

modular shelving units allows quick access to
stored items. According to Thomas Stipp, Head
of Logistics at Schunk: This is extremely important, as we need to quickly and accurately provide
A new, highly efficient parts storage system has 100 to 150 employees with the right products and
been created on a floor space of around 200 materials every day. Very heavy items are moved
square metres. It is designed to make full use with pallet trucks and electrically powered forklifts.
of all available headroom, and has capacity for There are additional modular shelving systems
5,000 products. Particular emphasis was placed with drawers in the open self-service area, where
on a compact, clearly structured layout with short employees can take whatever components and
picking routes and ergonomic processes. Stephan equipment they need.
Edeling, Project Manager at SSI Schaefer, states:
It wasnt an easy task, as the new facility had less Stipp concludes: We enjoyed a very positive working relationship with SSI Schaefer they tailored
floor space.
everything to our exact needs. We are now planTo reduce picking errors, SSI Schaefer installed fen- ning the next step SAP integration to make our
cing, creating an open zone and an enclosed zone. operations even more efficient.
The enclosed zone has a parts issuing desk and
All inventory is now
organised to maximise
efficiency: fast-moving
items are stored at
the front of the mobile
racking systems, with
slow-moving items at
the rear.



Faster picking through

optimised automation
SSI Schaefer has implemented an automated solution for LANDI Switzerland
to create high-availability storage and
streamline picking of small parts.
Dotzigen, Switzerland. Since 2002, SSI Schaefer has
been working hand-in-glove with LANDI Switzerland to
advance the enterprises intralogistics. Step-by-step,
LANDIs manual warehouse has been intelligently
re-designed and fitted with specialised equipment
and conveyors. Furthermore, WAMAS software has
been implemented to manage material flows.
In February 2014, SSI Schaefer installed a 60-metre
long, two-aisle automated small parts storage system
with a total of 24,000 container positions. Goods
were previously stored in conventional modular shelving systems. In this person-to-goods configuration,
pickers had to travel long distances which was timeconsuming. Today, picking is much more efficient.
The new small parts storage system is served by two
storage and retrieval machines, and 12 lifting beams,
and is integrated into the warehouses existing IT and
conveyor systems. Moreover, SSI Schaefers WAMAS
logistics software optimises putaway and picking processes.
The software also ensures the continuous, timely
flow of goods to new multi-purpose workstations,
where items are repacked after receipt, inventory data
is captured, and small parts are picked to order.
As Armin Kaufmann, SSI Schaefers Project Leader,
notes The multi-purpose configuration of these
workstations and their integration into material flows
ensures LANDI maximum flexibility for manual
A unique feature of SSI Schaefers solution is a fully
automated staging area for outbound items within
the small parts storage system. The area comprises
more than 100 storage positions, and guarantees
the seamless flow of sequenced containers to the
multi-purpose workstations in line with customer
orders. This design enables a throughput of 1,200
containers per hour, and allows rapid picking from
SSI Schaefers automated solution and its goodsto-person picking processes have helped us increase
our throughput from 60 items per worker per hour to
300 items, in conjunction with a zero-error rate, explains Urs Rogo, Logistics Project Leader at LANDI
Switzerland. We are very happy with how the project
went, and with the results.
The new 60-metre long, two-aisle
small parts storage system offers
a total of 24,000 container



Medium- and slow-moving

B and C products are
stored in a modular
shelving system on the
second floor.

Multi-tier storage solution

Burton-on-Trent, United Kingdom. NBTY is a global manufacturer and distributor, specialising in
high-quality nutritional supplements. The company supplies over 22,000 products under a number of its own and third-party brands. One such
brand is Holland & Barrett, a Europe-wide retailer
of vitamins, minerals, herbal supplements and organic health products. Holland & Barrett operates
over 620 stores in the UK and Ireland, and has a
successful and ever-expanding online business.

tensive conveyor system connects all levels and

zones, and moves order-picking and replenishment cartons to the picking floors. This conveyor leads to a series of packing benches, where
documents are placed in the cartons before they
are sealed and labelled.

The solution combines a multi-tier mezzanine

picking tower with pallet racking on the ground
floor, live storage picking on the first floor and
a combination of live storage picking and shelf
NBTYs high-street and online branches were picking on the top floor.
originally supplied by a distribution centre in
Burton-on-Trent, Staffordshire, where tasks were The new automated system is faster, more effiperformed manually. However, there was constant- cient and more accurate, helping us meet our
ly increasing pressure to keep up with daily de- online requirements. It also offers us a scalable
mand. To enable NBTY to reliably serve Holland & solution to our e-commerce enterprise, enabling
Barretts online customers, SSI Schaefer installed us to choose the level of automation to complean automated system at the existing distribution ment the level of demand, says Mark Kendrick,
centre, completely transforming the distributors Group Distribution Director at NBTY.
e-commerce capabilities.
In order to cope with NBTYs growing product
range and inventory, and to increase available
storage space, SSI Schaefer built a two-storey
mezzanine with pallet racking beneath it. This has
enabled NBTY to store bulk and replenishment
goods, both in large cartons and on pallets, at
ground floor level. In addition, SSI Schaefer installed a live storage system on the first floor of
the mezzanine for fast-moving A products, and
modular shelving on the second floor for mediumand slow-moving B and C products.
In the fully flexible picking zones on both floors,
shipping cartons are transported only to the
zones that hold order-required products. An ex-

Facts and figures

Project objectives:
End-to-end automation of material flows
Improved basis for e-commerce
Constant availability
Highly precise picking
Our scope of services:
Two-storey mezzanine with modular shelving system
Pallet racking, long-span racking
Eight storage and retrieval systems for pallets
Live storage system for cartons
Extensive conveyor system for cartons
WAMAS warehouse management software


Food industry

Turnkey high-bay warehouse

for frozen meatballs
Dafgrds frozen ready meals are stored at -28C in a state-of-the-art
automated warehouse.
To solve the problem of limited storage space at
their site in Kllby, Dafgrd tasked SSI Schaefer,
Giebelstadt, with the construction of a new cold
storage warehouse capable of storing products
at -28C. This high-bay facility will have a height
of 35 metres, and be equipped with a state-ofthe-art oxygen-reduction fire prevention system.
In addition, there will be six energy-efficient
Exyz machines for double-deep storage and retrieval. These devices will serve a total of approximately 30,000 pallet positions. Moreover,
SSI Schaefers scope of supply includes a new
distribution zone, WAMAS logistics software, and
a sophisticated conveyor system, directly linked
to the production plant.
3D graphic of
Dafgrds cold
storage warehouse in Kllby,

Kllby, Sweden. Swedish family-owned company Dafgrd has been developing and supplying
high-quality ready meals since the 1930s. Today,
Dafgrd is Swedens preferred brand of readymade meals, producing 40 million Billys pizzas
every year and 400,000 meatballs every hour.

Construction of the new cold storage warehouse

has just commenced, and is scheduled to be
completed in December 2015. It will significantly
improve the efficiency of Dafgrds logistics by
enabling easy delivery date monitoring, more
accurate inventory control, and faster loading of

Space-saving seafood
Tuticorin, India. Nila Sea Foods specialises in
seafood products, and offers a range of over
45 SKUs, including lobster, cephalopod, crab, fish
and shrimp.
Until recently, Nila Sea Foods stored its frozen
products in its own cold storage warehouse,
and at facilities operated by third-party logistics
Nila Sea Foods uses a mobile
providers. However, limited storage space made
racking system to store its frozen
seafood products.
it difficult to directly access all SKUs. Nila Sea
Foods mission is to supply its high-quality goods
on time, to ensure end-to-end product traceability,
and to safeguard the cold chain at all times. For this reason, SSI Schaefer was tasked with upgrading
the existing warehouse. A key role is played by a mobile racking system with a total of 1,830 pallet
positions. This has enabled more efficient use of available space.
The automatic racking system helps us to increase our productivity and reduce product damage.
Moreover, it consumes less electricity, takes up less space, and includes more safety measures.
This allows us to easily handle and trace products, explains Mr Chandran, General Manager of Nila
Sea Foods.


Food industry

WAMAS streamlines operations

at sub-zero
Rothenburg, Switzerland. Pistor is Switzerlands
leading supplier of food products to bakeries,
patisseries, and confectioners, and a key wholesaler within the restaurant industry. The business
recently tasked SSI Schaefer with constructing a
logistics centre for its fresh and frozen items. This
is the third time Pistor has chosen SSI Schaefer to
provide a state-of-the-art intralogistics solution in
1997, it implemented WAMAS, and in 2011 it built
a new distribution centre.
Pistors new 5000-square-metre freezer warehouse, nicknamed the Ice Cube by the staff,
is supported by WAMAS. WAMAS manages the
warehouses operations, logistics and support processes. The software is deployed to control the
flow of goods to and from more than 5,000 pallet
positions and 76,000 tray positions at a temperature of - 24C.
Incoming goods arrive on pallets, and data is
captured by WAMAS using handheld devices.
A conveyor system then moves the items to the
freezer area, where they are put away in doubledeep storage in the new two-aisle high-bay store.

Trays are put away

and picked by
means of a Schaefer
Miniload Crane
(SMC 1) storage and
retrieval system.

The items are manually transferred from pallets to

trays at repacking stations. A Schaefer Miniload
Crane (SMC 1) storage and retrieval system then
places the trays into a 12-aisle automated small
parts storage system.
The shipping area is the highlight of the new facility. The trays are automatically retrieved from the
small parts storage system on trolleys in preparation for shipping. They are sent to a sorting unit
via buffer conveyors, and are organised into a defined sequence by WAMAS before they arrive at
the packaging area. Transfer from the small parts
storage system to the ergonomic packaging area
is automated from end to end. This enables packaging tasks to be performed at above zero temperatures (1C), creating a more pleasant working
environment. Due to the compact sequencing of
the trolleys, the frozen products are only exposed
to above-zero temperatures for a limited time.
The Rothenburg project was complex, with a high
degree of automation. Products need to be stored
at sub-zero temperatures, and government agencies imposed strict requirements. Despite these
challenges, it was very successful, states Richard
Betschart, Head of Logistics at Pistor.

WAMAS manages the warehouses operations, logistics

and support processes.


The design of the

high-bay warehouse
with channel storage
increases Tines storage flexibility and
inventory turnover for
new products.

High throughput, low temperature

Jren near Nrb, Norway. Tine processes 200
million litres of milk a year to manufacture some
300 dairy products. This creates significant
storage and picking challenges, but SSI Schaefer,
Giebelstadt, is up to the task.

The SRMs are equipped with shuttles as loadhandling devices, enabling three- to four-deep
storage in the rack channels. The HBWs design,
with a channel storage system, improves storage
flexibility and throughput of newly introduced products, explains Ingvar Lge, manager of the new
At the core of SSI Schaefers logistics solution is a warehouse in Jren. A 400-metre long pallet contemperature-controlled high-bay warehouse (HBW), veyor system connects the HBW with the producwith close to 7,200 pallet positions. Due to the tion and shipping areas.
sensitive nature of its goods, the cooling system is
equipped with an oxygen-reduction fire prevention SSI Schaefers WAMAS logistics software mansystem. Putaway and picking tasks are performed ages and monitors warehouse processes. The
by four storage and retrieval machines (SRMs), cold chain is maintained through a combination
with a throughput of 33 pallets per hour. The of automation, software, and storage and picking
SRMs and their components are ideal for oper- systems. Furthermore, WAMAS helps streamline
ation in temperature-controlled warehouses, the entire supply chain, from farm to supermarket
states Peter Lambrecht, Head of Project Manage- freezer.
ment at SSI Schaefer.

Pasta made in Canada

Brampton, Canada. Founded in 1989, Italpasta has achieved outstanding
success through its commitment to excellent service, quality, and customer
satisfaction. Its team, including ten pasta specialists with extensive experience in their craft, ensure that Italpasta enjoys wide recognition in Canadas
food service sector, and is the No. 1 retail pasta brand in Ontario.

A conveyor system
moves cartons from
the packaging zone
to the buffer area.

However, Italpastas continuous growth created real challenges for its packaging department. Space constraints in production, and poorly structured
warehouse processes posed a risk to employee and food safety.
For this reason, Italpasta tasked SSI Schaefer with automating and restructuring the corresponding processes without disrupting ongoing operations. SSI Schaefers solution was
to construct a bridge, with two integrated conveyors, to connect the manufacturing plant to the adjacent building used to hold finished goods. The conveyors move cartons from 21 packaging lines to the
buffer area, where they are sorted and stacked before being sent to one of four automated palletising
stations. Here, they are palletised, shrink-wrapped, labelled, and prepared for shipping.
The solution has enhanced efficiency, improved staff working conditions, and increased space available for equipment now, there is nothing standing in the way of Italpastas progress.


Food industry

Vietnams high-tech dairy distribution centre

WAMAS software and process
automation ensure high throughput for Vinamilk in Vietnam.
Binh Duong, Vietnam. Vinamilk is Vietnams leading dairy product manufacturer, processing 400
million litres of milk annually. The company meets
much of the countrys market demand, and has recently established the Ben Cat District Facility on
a 200,000-square-metre site. This huge factory
requires sophisticated intralogistics to ensure the
smooth flow of goods.
In the manufacturing department, the dairy products
are packaged in Tetra Paks. These are then boxed,
shrink-wrapped and palletised, before being moved
to a smart warehouse, built by SSI Schaefer, via two
transfer stations. The key to process automation
within the warehouse is a rail-guided vehicle (RGV)
system, with a total length exceeding 370 metres,
and 15 vehicles. The RGV moves pallets from the
manufacturing department to any required storage
position within the logistics centre. It is the first time
that SSI Schaefer has installed an electrified RGV
system for intralogistics flows in South-East Asia,
explains Carsten Spiegelberg, General Manager for
Systems and Automation, Schaefer Systems International Pte. Ltd., Singapore.
Each RGV carries two pallets simultaneously at a
speed of 90 metres per minute to the transfer spurs
for the automated storage and retrieval machines
(SRMs). Eight Exzy SRMs serve some 28,000 pallet
positions within the earthquake-proof high-bay warehouse.
For the outbound process, the pallets are transferred via a conveyor to eight shipping lanes. A vertical conveyor moves pallets that require pre-picking to an upper floor. WAMAS logistics software
ensures route-optimised picking while taking into
account constraints imposed by the need for stable,
volume-optimised pallet loads. Once picking is complete, the logistics software sequences the movement of pallets to the shipping area on the lower
floor in line with customer orders.
Despite highly complex goods flows, it is possible to
move 188 pallets per hour to the shipping department. SSI Schaefers logistics software streamlines our processes and accelerates throughput;
moreover, it has reduced our error rate to almost
zero. The solution as a whole provides excellent
support for our growth strategy, emphasises Trinh
Quoc Dung, Vinamilk Factory Manager.

Eight energy-efficient
Exyz SRMs perform
pallet putaway and


Logistics service providers

Innovative combination
of systems

SSI Schaefer has implemented

a flexible, state-of-the-art
solution that enables highly
efficient processes for logistics
specialist Khne + Nagel in
Utrecht in the Netherlands.

Khne + Nagel, the global logistics player, tasked SSI Schaefer with creating a
highly flexible and efficient distribution centre for its business operations in the
Netherlands. The result is a 12-aisle high-bay warehouse for foodstuffs, with
an integrated Orbiter shuttle system, an electrified rail-guided vehicle (RGV)
system and conveyors with a total length of around one kilometre. The facility
also features layer-picking robots with innovative grippers.
Utrecht, the Netherlands. Worldwide, Khne + Nagel
offers its customers approximately seven million
square metres of storage space including more
than 33,000 square metres in Utrecht, the Netherlands. SSI Schaefer, Giebelstadt, Germany, was
contracted to create a logistics centre for storing
foodstuffs for multiple customers. The result is a
facility that combines a variety of highly advanced

The deployment of two picking robots with

innovative grippers enables the automated
picking of individual pallet layers.


The new 12-aisle high-bay warehouse has capacity

for 43,700 euro and 35,900 industrial pallets,
stored four- and five-deep. The racking channels
have been divided into dynamic FIFO-friendly (firstin first-out) half channels to allow direct access to
front-facing pallets without the need for re-slotting.
This required the installation of a non-standard
load-handling device. The solution was a combination of automatic storage and retrieval machines
(SRMs) and an Orbiter shuttle system. This enabled the integration of channel storage into the
high-bay system. However, in comparison to conventional channel storage, there is far greater flexibility in terms of the range of products that can be
stored. This is particularly advantageous for foodstuffs, with their strict sell-by dates. The SRM acts
as a docking station for the Orbiter shuttle. Once
the pallet has been loaded onto the SRM, the SRM
travels into the corresponding aisle, and stops in
front of the racking channel defined by the logistics
software, enabling the Orbiter shuttle to put away
the pallet in precisely the right position within the
high-bay system.

Logistics service providers

SSI Schaefers WAMAS software intelligently

manages all aspects of materials flow for putaway and retrieval processes, picking and crossdocking. In the receiving department, the pallets
are subject to automated checks on contours,
excess weight, height class, and base integrity. At
the same time, a plausibility check is performed,
including a weight comparison, on the basis of
product master data. The electrified rail-guided
vehicle system then conveys inbound pallets to
the transfer stations to the SRMs.
The electrified rail-guided vehicle system describes a circular route, serving the conveyors for
all workstations in the distribution centre. Managed by the logistics software, this system employs 24 vehicles to move inbound goods to spurs
for the SRMs or, for cross-docking, to the staging
lanes ready for shipping, or to integrated picking
stations. To this end, the distribution centre has
six transfer stations to the roller and chain conveyors. A conveyor system of a total length of one
kilometre was installed in front of the 114-metre
side of the high-bay warehouse. Rotary conveyors
are used to feed this system with cross-docked
pallets from the receiving department, and with
pallets retrieved from the high-bay warehouse.
The pallets are then moved directly to the shipping area, or to the layer-picking robots.
The picking robots are a key feature of the project, and make use of innovative gripper technology. They can auto-pick individual layers from one
or two source pallets, and position them onto
up to four target pallets. The logistics software
must manage the full pallets retrieved from the
high-bay warehouse in a sequence that enables
each one to be used for as many target pallets
as possible, but while ensuring these outbound
pallets are completed rapidly to avoid creating
a bottleneck.
The design of the layer picking robots, and the
configuration and management of the goods flows
to and from the robots, are a vital feature of the
entire distribution centre, states John Pelzer,
Technical Manager at Khne + Nagel Netherlands. They were key to our decision to award
the contract to SSI Schaefer.

The high-bay warehouse is 34

metres high, and has a total
of 43,700 positions for euro
pallets, and 35,900 positions
for industrial pallets.


Special feature



Te c h


it / t
r o f is a
R p ti m
S y ste m


r ta

por t



e Par ts Serv

S er v

However, there is an answer. Within the scope of a

broad portfolio, SSI Schaefers Customer Service
& Support (CSS) division offers timely advice and
assistance, helping businesses to run smoothly.


er a ini
tif n g
ic a &
tio n

Giebelstadt, Germany. Warehouses play a significant role in any logistics infrastructure. However, the
components deployed in these facilities are, over a
typical period of seven to 15 years, overtaken by
technological advances, rendering them obsolete.
They are often no longer able to effectively support
the latest business processes and growth strategies. The consequences are high operating costs,
inflexibility, and reduced competitiveness.


Maximum availability of all subsystems and

responsive customer support are crucial to
keeping complex logistics processes up and
running. SSI Schaefer is fully committed to
these objectives.


Made-to-measure customer
service and support

ent ance
e ten
P in
ent Mainte

Its extensive range of services includes technical

support, help desks, system monitoring, inspection and maintenance, on-site support, safety
checks, the provision of spare parts, consulting
and training. CSS works closely with its customers
to develop tailor-made service offerings geared
to their current requirements and potential future
It is not always necessary to entirely replace a
legacy infrastructure. In many cases, a retrofit
is sufficient to provide the required warehouse
efficiency it is a quick and cost-efficient way to
upgrade intralogistics systems without interrupting
ongoing operations.
Often, the basic mechanical structure and key
components can be retained and reused. However,
older facilities often lack up-to-date control technology, energy-efficient drives, and modern conveyor
components. Moreover, state-of-the-art IT systems
can often bring major improvements to entire
processes and goods flows, ensuring greater productivity and higher quality. SSI Schaefer provides
new and established customers with expert advice
on how they can best re-engineer their intralogistics while protecting existing investments, and
minimising cost, effort and disruption.
This leads to greater reliability, increased uptime,
and more efficient use of resources. This publication features two CSS projects that illustrate how
processes and operations can be streamlined in
this way.

Skilled service engineers

are available at all times to
provide end-to-end on-site


Special feature

Seven times faster

with RFID tracking
Conversion at A. Kempfs distribution
centre saves up to eight man-hours
per day.
Balingen, Germany. Beverage logistics specialist
A. Kempf is a subsidiary of supermarket chain
Edeka Sdwest. From its warehouse in Balingen,
Kempf services 125 customers per day up to
110 delivery routes. This calls for extremely efficient processes. However, these were hampered
by the legacy identification and tracking methods.
For example, manual scanning of incoming
pallets was very time-consuming. As a result,
SSI Schaefer, Giebelstadt, converted the goods
receipt processes to RFID (radio frequency identification). Each RFID transponder (also known as a
tag or chip) has a unique identifier, and can store
significantly richer data than barcodes. Moreover,
they do not require line of sight.

cards in the holders. During the shift, the warehouse management system (WMS) transmits the
picking and transfer jobs directly to the onboard
terminals. Both the completion of pallets for putaway and the transfer of pallets to conveyors are
reported to the WMS via RFID, and coordinated
via the material flow control system. The new
Three industrial UHF RFID read/write devices RFID technology delivers huge time savings and
were installed at the Balingen distribution centre creates seamless putaway processes.
to detect the picking trucks and forklifts at the
three pallet receiving stations. In addition, each Thanks to this powerful technology and high-peremployee was given a personal identification card formance components, data collection is reliable
with an RFID chip, and all trucks used for pallet and error-free, reports Patrick Zurheide, who
receipt were fitted with special card holders.
manages Kempfs distribution centre in Balingen.
Thorough preparation enabled SSI Schaefer to
At the start of each shift, employees log on to complete the conversion in just one week
the terminals on their trucks, and place their RFID without disrupting ongoing operations.

Three industrialstrength UHF RFID

read/write devices were
mounted at the pallet
receiving stations to
track picking trucks
and forklifts.

Teamwork was the key to success

SSI Schaefer has expanded Oriflames distribution centre in Poland.
Piaseczno, Poland. Oriflame specialises in innovative, natural Swedish cosmetics, and markets its products via approximately three million
independent Oriflame beauty consultants.
With consultants securing ever-increasing order
volumes, and online sales growing as well, the
shipping process was experiencing significant
delays. The solution was to expand the companys logistics centre. SSI Schaefer, Graz,
Austria extended the conveyor infrastructure,
installed an automated carton conveyor line in the
shipping department, modified the existing IT, and
introduced a new labelling system.

The challenge was to enhance existing installations while the logistics centre continued to operate at full capacity, reports Robert Ranftl, who
managed the project for SSI Schaefer. To avoid
disruptions in the shipping department, work was
mainly carried out at night.
Greater capacity has produced positive results:
Oriflame can now ship products promptly and reliably, even during peak periods. The entire project
was conducted to the highest professional standards. It was the best weve ever been involved
in by far, says Lukasz Kielczewski, Operations
Manager at Oriflames logistics service provider,
Logwin Air + Ocean, Poland.


Inside SSI Schaefer

Growing demand
for upgrades
Klaus Reichert, Head of Fulfilment,
Customer Service and Support at
SSI Schaefer, Germany.

Upgrades and retrofitting have become a hot topic in

intralogistics. They are often advisable after about
10 years of service, depending on the industry and the
type of equipment. The goal is to safeguard or raise
productivity, and to ensure efficient use of resources.
In an exclusive interview, Klaus Reichert answers the
key questions.
What does a retrofit package from SSI Schaefer entail? And how do you go
about the tasks involved?
We have a dedicated upgrade team within the Customer Service and
Support department. They offer a comprehensive portfolio. Services include
the development of customer-specific improvement plans, with detailed capital expenditure budgets, and energy-efficiency and IT solutions, for example
upgrades to warehouse management and equipment control systems. We
often also replace drives and mechanical components. Generally, customers
approach us first, and we then assess the existing logistics infrastructure in
situ. Together, we develop an upgrade plan designed to make systems ready
for future challenges. We then begin with implementation but with a focus
on minimising downtime.

SSI Schaefer service engineers performing

upgrade work on a conveyor system serving
nine aisles in an existing high-bay warehouse
at Zott in southern Germany.

How much demand is there for upgrades, and is it on the rise?

Demand for the retrofit of state-of-the-art equipment to existing intralogistics
systems remains high. It is driven by technological progress on the one side
and by the age of the existing systems on the other. Hand-in-hand with the
customer, we perform in-depth analysis of the legacy systems. Our goal is to
make the most of available space and resources, and to maximise uptime
and throughput within existing distribution centres.
Do you offer upgrades and retrofits for third-party legacy equipment?
We have the skills to quickly and reliably modernise both SSI Schaefer and
third-party warehouse and production systems. This can entail replacing components, adding new systems, and upgrading the IT. New materials flows are
tailored to existing production plants. Modernisation improves operational
reliability and raises warehouse availability for both new and existing customers.
Is the demand for retrofits greater in some industries than others?
There does not seem to be any great variation between individual industries.
We are seeing growing demand across the board.
Can customers expect disruptions to ongoing operations during an upgrade
We are very focused on working with our customers to find ways of minimising
the impact of implementation projects on operations. We plan for any work
that will entail downtime for mission-critical systems or the entire facility
well in advance, and where necessary we schedule work for weekends or
holidays. We are keenly aware that downtime can have a severe impact upon
the customers business, but we can largely avoid it.

The storage and retrieval systems at

SKF in Berlin were, with the exception
of the mast and the track, completely
disassembled during an upgrade.


Inside SSI Schaefer

Production plant
expansion in Asia

The Navette is equipped with two load-handling devices, one positioned above the
other. This enables the system to put away and retrieve items simultaneously
performing two actions in just one cycle.

Navette the scalable,

multi-level shuttle

Reng gam,
SSI Schaefers expanded steel production plant went into operation in February 2014. A new rolling mill, the same
type used by the parent company in
Germany, will soon process all profiles
for high-bay racking systems which
may be up to 40 metres in height. Additionally, systems for preparing special
steelwork profiles will be installed.

SSI Schaefers innovative new product, Navette,

continues the enterprises tradition of providing
efficiency-enhancing solutions for fully automated
Giebelstadt, Germany. The Navette from SSI Schaefer is an innovative,
independent warehouse vehicle that combines the advantages of both
a shuttle and a storage and retrieval machine. It transports totes, trays,
and cartons.
The Navette is integrated into the steel framework of racking aisles in automated small parts storage systems. Guided by travel and support rails, a
single shuttle serves up to eight levels of storage, including two levels
simultaneously. The Navette is equipped with two load handling devices
(LHD), such as carton grabs, arranged one above the other so each can
access a separate level. Additionally, each LHD can transport two trays,
totes or cartons at a time. As a result, the Navette performs a total of
two actions within a single cycle, for four items rather than two actions
consecutively without deadheading. The concurrent putaway and retrieval
while the Navette shuttle remains at one position in the racking reduces
travel time and doubles process efficiency.
The Navette has been integrated into an end-to-end system based on
SSI Schaefers 3D-MATRIX Solution. The shuttles are combined with
Navette lifts and vehicles, and conveyors, to move goods in the X, Y and
Z axes. All these components are efficiently designed to operate independently but simultaneously.
Furthermore, all components can be combined in almost any number
and configuration, without having to completely re-engineer the system
as a whole. Subsequent expansions can be completed without disrupting
normal operations. The result is a solution offering highly dynamic goodsto-person picking, and putaway, buffering and order-based sequencing.
The Navette can be scaled precisely to customers specific needs. As a
standard SSI Schaefer system, the multi-level shuttle is a secure investment. It enables access to a wide range of SKUs in storage channels, and
highly efficient workflows due to its concurrent processes it is a quantum
leap forward in innovative design and warehousing technology.

We are seeing an increase in enquiries

for high-rise racking systems due to
rising land and labour costs. Shipping
heavy steel profiles halfway around the
world is obviously not cost-effective.
To cater to growing demand from the
Asia-Pacific Region, the Middle East
and Africa, we have decided that Asia
should become a competency centre
for the design and supply of these
systems. Our Malaysian engineers
have been trained to undertake the
structural designs and to prepare fabrication drawings using the German CAD
program, states Brian Miles, Regional
Managing Director.
In 2011, SSI Schaefer built a
5,000-square-metre plant for manufacturing conveyor systems and picking
equipment. Due to rising exports, storage capacity was increased by 2,000
square metres in 2012. The site in
Simpang Renggam has grown to a size
of 40,000 square metres, with a headcount of approximately 500. Additional
expansion comprising a further 5,000
square metres of warehouse space
plus offices is already underway.


Serving up highly efficient beverage logistics

In the food industry, fast and reliable delivery is a must. And that is where
SSI Schaefers Lift & Run system comes into play. The innovative system
puts theory into practice. A shuttle serves channel storage facilities,
creating an exceptional, cost-effective solution for handling pallets.
Highly dynamic, scalable, compact and energy efficient, the system can
be tailored to specific needs.

About update
Published by (responsible for content): SSI SCHFER / FRITZ SCHFER GMBH Fritz-Schfer-Strasse 20 57290 Neunkirchen/Germany
Public Relations / editorial team: Angelina Kuhn email
P. O. Box 7009 10021 Westlake Drive USA-Charlotte, N.C. 28241 Phone +1/704/9444500 email
update en/us 0344-042015-w 2/042015 Printed in Germany by Griebsch & Rochol SSISCHFER Products featured in articles may be subject to change and technical modification. Errors and omissions excepted.