The new logistics centre will cover all three temperature zones and be equipped with modern sequencing workstations, buffer lanes and staging areas for trolley containers. Automation will increase efficiency, reduce picking errors, improve working conditions and ergonomics at workstations, and ensure the company's long-term growth. The deep-freeze and dry storage facilities will be designed as 3-aisle automatic small parts warehouses with storage and retrieval cranes. The fresh warehouse will use KlinCAT, a powerful multi-level shuttle system that ensures maximum capacity and efficiency. Klinkhammer was initially contracted by Innstolz to draw up the logistics planning for a customised, manufacturer-neutral logistics concept that reflected the order structure, integrated growth forecasts and optimised material flows from goods receipt to goods dispatch.
At the heart of the new automated storage systems are the picking zones with sequencing workstations and buffer sections at temperatures of 2 to 7 degrees Celsius. Picking takes place at above-zero temperatures, which significantly improves working conditions compared to manual deep-freeze warehouses. This not only makes work easier, but also ensures that the goods are assigned to the customer order in the correct order on trays using conveyor technology. This optimises the loading of trolley containers, whether separated by customer using intermediate shelves or sorted in the optimal order from heavy to light, thus avoiding damage and subsequently optimising delivery sorting by route. To save time when picking trolley containers, it is possible to pre-pick goods. Order containers are loaded with the correct goods in advance and stored in the automated warehouse until the trolley containers are ready to be loaded. This extends the cut-off times, optimises the entire shipping process and improves customer service.
The automated warehouse comprises a 3-aisle deep-freeze warehouse and a dry warehouse. The fresh produce warehouse is designed as a 2-aisle multi-level shuttle system with three KlinCATs stacked on top of each other, which can access up to six container levels. A total of 58,000 tray spaces are available in the facility. To support the planned growth, there are also plans to add another aisle to the automated deep-freeze warehouse, which will increase the total storage capacity to 65,000. The KlinCAT multi-level shuttle is characterised by its compact design, low weight and high throughput. It also offers low approach dimensions for high storage density and low investment and maintenance costs.
As a family-run company with over 75 years of experience, Innstolz focuses on continuous expansion and modern food trends. In addition to classic fresh and frozen goods, the company is constantly expanding its range to meet the needs of its customers. Customers can choose from a total range of over 18,000 items. Service, quality and delivery reliability are the top priorities. All orders placed the day before are delivered to the customer the following day and go straight to the kitchen, counter or shelf. Over 35 refrigerated trucks with multi-chamber temperature control deliver food daily within a radius of around 160 kilometres to Lower Bavaria, the Upper Palatinate, Upper Bavaria and Upper Austria. With the new automated warehouse, Innstolz is setting an important milestone for efficient, future-proof and sustainable logistics.
The entire process is controlled and continuously monitored by the KlinkWARE warehouse management software. The system is supplemented by a software connection to manual pallet warehouses, which allows large quantities or bulky items to be efficiently integrated into the logistics process.
