Dennree, located in Töpen near Hof, is the leading German wholesaler for organic food and natural cosmetics.
For the replenishment storage, Klinkhammer has been awarded a contract by Dennree for supplying a 3-aisle high-bay warehouse. Goods receipt takes place on several levels by the host system. Following notification, the pallets are allocated to the aisles. This allocation takes into account the availability of the automated storage and retrieval cranes, the degree of capacity utilization of the racking system and how articles are distributed across the aisles.
The distribution according to the replenishment strategy is done by carriages in the pre-zone of the automated aisles. The high-bay warehouse has been designed for double-deep storage and incorporates three height classes. The overflow mechanism is saved in the material flow computer and can be parameterized.
As long as possible, always only the same articles with the same BBD are stored in the warehouse at multiple depth to minimize any relocations. If articles feature not the same BBD with an empty storage location in front or if no completely empty channel is available, the occupation is mixed. The goods in stock are administered as to quality, batch and BBD and tracked accordingly. Always only entire pallets are retrieved – for customer orders and for refilling the order picking as replenishment. Order data transferred by the host define the process.
The pallets are retrieved and then placed on gravity lanes in the pre-zone. The lanes are arranged in form of a fan and are administered according to capacity and order allocation. The feeding conveyor features a storage capacity of more than 50 pallets. Based on predefined criteria such as batch number, BBD (best-before-date) or residual time and overflow scenario, DC21 is responsible for allocating the stock for retrieval. During this process, the availability of the aisles and devices and the load distribution are taken into account – the distribution makes it all possible.
Headquartered in Hagenow, our customer is active in the production of sweets.
Due to the requirements, a high-bay warehouse with four aisles was needed featuring around 11,000 storage locations for Euro pallets. To ensure greatest possible flexibility and warehouse utilization, pallets of various height classes should be stored.
The incoming goods from the production are handled automatically via AVIS by SAP or via the information from the article master data. At a reworking station, special cases (mixed pallets, shape check etc.) are treated during the goods receiving process. Usually, the receipt of incoming goods occurs automatically by scanning the pallet and product label on the conveyors.The product label from production contains data for batch management as well as information on the BBD. Then, a pallet stretch wrapper – which is integrated in the conveyor system – wraps the pallets with a foil applying various wrapping patterns to gain stability and to satisfy fire prevention regulations. When storing, the articles are distributed across as many aisles as possible to ensure fastest possible handling during retrieval (parallel operation). Beyond that, attention is paid to the fact that the load is spread equally over the entire floor surface of the high-bay warehouse (statics) and traverse and field loads are not exceeded. A double carriage ensures the distribution to and from the four automated storage and retrieval cranes. The picking process in the high-bay warehouse is triggered by SAP. Retrieval occurs such that goods are of the same batch, using six picking lanes which are filled in single-order mode via their capacity. By means of scanning and radio data transmission, goods are then directly loaded onto the trucks.
Deep-freeze store, at -22°C
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.To ensure high energy efficiency, the power requirements of the system were harmonized with the power requirements of the air conditioning to compensate power peaks in current consumption. 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.
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. Branch Reference (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.