The Klinkhammer Group has built an automated deep freeze warehouse for temperatures down to -22°C for the company Frischdienst Walther, a food delivery wholesaler located in Germany, supplying restaurants, hotels and large-scale consumers. Thanks to the tray technology used, it is now possible to store a wide variety of different package sizes in a cost-effective manner. The focus is on short distances, a minimum cooling loss and significant increase of efficiency in the warehouse through automation. The company Frischdienst Walther guarantees highest reliability during order picking of the goods ordered thanks to the technical support provided by the"Pick-by-Voice" technology. By means of the electronic routing and scheduling system and thanks to the own vehicle fleet equipped with two-chamber cooling systems, delivery deadlines and cold chains are fully complied with.
The orders of customers from restaurants are often placed at very short notice and more than 95% of them are delivered within 24 hours. Given the rapidly growing need for deep-freeze products, Frischdienst Walther decided to automate its processes in the deep-freeze warehouse by contracting Klinkhammer. The aim was to considerably increase the capacity, speed, efficiency and flexibility while at the same time making optimum use of space.
For the just-in-time delivery Frischdienst Walther may now benefit from a modern, automated high-bay warehouse featuring two aisles, providing 9,120 tray storage locations. The throughput amounts to up to 150 storage and retrieval actions per hour. The specialists of Klinkhammer use trays as loading/storage aids as these trays offer highest possible flexibility during the storage process of packaging units of different size and height. The order picking workstations,which are connected by means of a conveyor loop in the pre-zone of the automated deep-freeze warehouse, guarantee an ergonomic handling of the trays. The maximum height of the small parts warehouse totals to 7.60 m to fully comply with the statutory fire protection requirements. Thanks to this height limitation it was possible to avoid the installation of complex and costly sprinkler systems or the inertisation of the warehouse. The machines and systems have been designed to best fit the requirements in deep-freeze stores. Deep-freeze suitable technical components such as special drives, control cabinet heaters, appropriate photoelectric barriers and sensors as well as temperature-resistant plastics guarantee high system reliability even at temperatures of minus 22°C. The Klinkhammer Warehouse Management System, including the material flow computer,is linked to the already existing ERP system via interfaces to ensure transparency and high efficiency.
The Advantages for the Customer
All warehouse sections and functional areas are linked such to ensure shortest possible distances and such that the loss of cooling as well as the introduction of heat and humidity is kept at a minimum level. Thanks to automating the warehouse, it was possible to achieve a significant efficiency increase when handling different package sizes and weights. Reference Sheet (Pdf)
Deep-freeze store, at -28°C
Formerly built for the industrial bakery Gramms, Lantmännen Unibake operates a deep-freeze store in Suhl. At -28°C bakery products are stored.
One double-deep aisle with pallet high-bay racking and one aisle with an automatic small parts warehouse for cartons on trays take up the products from production. The goods are entered manually by forming pallets or though fully automated loading of pallets and trays using a palletizing robot.
This robot picks up product cartons from three feeder lanes, which follow the three production lines with packing machines, and then stacks them on pallets and trays according to the packing pattern for the carton type. The trays are pre-labeled, whereas the labels for the storage of pallets are produced automatically. By means of palletizing the goods are married to the load carrier. The production data such as batch, date of production and BBD complete the product information. Retrieval takes place by manually selecting the goods. The goods made available are picked in the warehouse pre-zone at +1°C and prepared for the sequenced loading.
The automatic small parts warehouse is used for picking small quantities for the chain store. Here, mixed pallets or cartons are created which then are shipped or picked up. It is also possible to remove partial stock quantities from pallets; however, shipping the complete pallet is preferred.
The process from the request for goods until shipment in Iso-container refrigerated trains or swap trailers must take place very quickly, as goods must not start to defrost. Thanks to the minimum remaining shelf life of the articles, the respective articles are automatically blocked, if the minimum remaining shelf life is remained under. Production batches and BBD are traced completely from start of production until delivery.