References - Food

Data and Facts

  • 3-aisle high-bay warehouse, double-deep (52 m length, 27 m width, 23m height)
  • 5300 pallet storage locations
  • Storage/Retrieval: 156/110 pallets/h incl. 50 relocations
  • 60 m feeding conveyor with a storage capacity of about 50 pallets
  • Warehouse management system DC21 and material flow computer

Dennree GmbH

The Customer
Dennree, located in Töpen near Hof, is the leading German wholesaler for organic food and natural cosmetics.

The Requirements
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 euro pallets available in 4 different height classes 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 Solution
The distribution according to the replenishment strategy is done by carriages in the pre-zone of the automated aisles. Prior to replenishment, load safety is ensured by automatic contour and overweight controls. The high-bay warehouse has been designed for double-deep storage and incorporates four 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 featuring a length of 60 meters has a storage capacity of about 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.

Data and Facts

  • Plant design
  • High-bay warehouse (4 aisles) with around 12,000 storage locations
  • 4 fully-automated storage and retrieval cranes
  • Retrieval performance of up to 1,770 pallets/day
  • 6 picking lanes
  • Material flow computer with storage location management and SAP-connection
  • Special indoor climate in the high-bay warehouse thanks to innovative, new design of the outer facade
  • Control engineering and visualization (ConVis)

Trolli GmbH

The Customer
Headquartered in Hagenow, our customer is active in the production of sweets.

The Requirements
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. By means of special storage strategies, a fast parallel operation of retrieval across six order picking lanes should be possible.

The Solution
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. 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. 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.

[Translate to English:] Klinkhammer Group

Data and Facts

  • 3-aisle automated high-bay warehouse, 11,000 pallet storage locations
  • 2-aisle automated small-parts warehouse for 8.800 containers
  • Manual cold storage, 300 pallet storage locations
  • 10 production workstations, connected by conveyors: filling, transferring, weighing, mixing
  • Klinkhammer material flow calculator and system visualization
  • 6 gravity loading lanes for pallet, 5 loading ramps

HÜGLI Holding - Intelligent Production Supply

The Customer
Hügli Holding AG, an international Swiss food company with 1,350 employees, and the company Klinkhammer have built and put into operation, at the Radolfzell location, an automated small-parts and high-bay warehouse in silo-type and a cold storage. Hügli Nahrungsmittel GmbH has invested about 30 million euros in the expansion of the Radolfzell location in Germany. According to the motto "culinary expertise, creativity and speed", the products of Hügli range from antipasti, bouillons or burgers to ready to serve meals up to sports nutrition, soups or seasonings.

The Requirements
The focus of the new production building with connected warehouse for the mixing of semi-finished products is on the process-optimized conveyor connections between the different warehouses and the mixing facility and order picking. The aim is to optimize material flows for a fast production supply and to shorten delivery times.

The Solution
The new construction in which Klinkhammer Group has implemented the intralogistics comprises the mixing facility and a connected automated high-bay warehouse with more than 11,000 storage locations for raw materials, packaging and finished products. A two-aisle automated container warehouse (ASPS) comprising about 8,800 containers is also connected to production by conveyor technology. The container warehouse is used for minimum quantities and as an order combination buffer for premixed batches. Comprising the conveyor connection of 10 production workplaces, the raw material silos, the cold warehouse with 300 pallet bays and 6 gravity dispatch lanes, one of the most modern production plants for dry mixed products in Europe has been built.

The Advantages for the Customer
The system's distinctive feature is the optimization of the complex material flows. The conveyor connection of the 3 warehouses, the raw material silos and the production and order picking areas located on 3 levels significantly shortens the distances and increases the process safety. The automation also ensures the required performance and quality. Until now, 30,000 tons annually have been produced in three-shift operation. Now, a capacity of 40,000 tons in two-shift operation is available. A safe charging of the mixing facility with different raw materials and premixed batches, the weighing and filling into stainless steel containers, the return of the goods to the warehouse, as well as the empties management are complex processes which are perfectly coordinated in the IT infrastructure. The automation and digitization set new standards in quality assurance and increase the efficiency of the processes. Reference Sheet (PDF)

Klinkhammer Group

Data and Facts

  • Automated, 2-aisle deep-freeze store down to -22°C
  • 9.120 tray storage locations
  • storages and retrievals: up to 150/h
  • Klinkhammer warehouse management software and material flow software
  • Interfaces to the ERP-system
  • Consideration of batches and best-before-dates

Frischdienst Walther - Deep-Freeze Store

The Customer
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 Requirements
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.

The Solution
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)

Data and Facts

  • Warehouse management software KlinkWARE® incl. material flow calculator
  • Pallet flow racks in the automated pallet high-bay warehouse with 2 automated storage and retrieval cranes
  • Manual pallet rack spaces, shelving racks and block storage

Rabenhorst - Beverage Industry

The Customer
Rabenhorst stands for brand products with more than 200 years of experience in the direct juice sector. Besides fruit juices, Rabenhorst offers natural food pastry and food products for people with intolerances. More than 1200 tons of berries, 1400 tons of apples and 250 tons of cherries are processed into approx. 10 million liters of direct juice every year. If all Rabenhorst bottles from the high-bay warehouse were placed next to each other, they would cover a distance of 210 km.

The Requirements
The aim is to digitalize the processes and to administer all logistics locations in one software in order to significantly increase the transparency and efficiency in the warehouse. Overall, 420 juices and smoothies, which differ in pack size, bottle size and labeling, are stored. Added to this are 130 articles of pasta products and baked goods as well as different display packages, which are located at external service providers in external warehouses.

The Solution
The existing Klinkhammer warehouse management software in the automated high-bay warehouse is connected to the new software generation KlinkWARE® and the new logistics center in Anhausen as well as the manual external warehouses are administered by KlinkWARE®. KlinkWARE® with its Microsoft SQL server database is connected to the existing ERP system. Whereas until now the current Klinkhammer software was only responsible for the administration and control of the automatic flow-through storage system in Unkel, from now on KlinkWARE® will be rolled out for the entire goods receipt processing and order picking.  3500 storage spaces and order picking stations in the logistics center Anhausen are also integrated. Two further external warehouses at service providers are partly connected online and partly via EDI. KlinkWARE® will not only implement the requirements of the food retail trade, e.g. the compliance with batches and best-before dates, but also multilevel supply chains, among others, which visualize display production and special processing. The manually operated external warehouses are own as well as external replenishment warehouses at forwarding agencies and wholesalers, which either directly supply the regional trade or shipment can be carried out centrally from a warehouse by consolidating orders.

The Advantages for the Customer
KlinkWARE® manages several external warehouses. Thus it is possible to split up larger production batches, outsource the overstock and ship it directly.

Data and Facts

Deep-freeze store, at -28°C

  • One double-deep aisle with pallet high-bay racking, 1496 storage locations
  • One aisle with an automatic small parts warehouse for cartons on trays, 3974 storage locations
  • Palletizing robot
  • Warehouse pre-zone at +1°C

Lantmännen Unibake Germany GmbH & Co. KG - Deep-Freeze Store

The Customer
Formerly built for the industrial bakery Gramms, Lantmännen Unibake operates a deep-freeze store in Suhl. At -28°C bakery products are stored.

The Solution
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.

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