References - Production

Data and Facts

  • 2-aisle, automated pallet high-bay warehouse in silo construction with 4,900 storage spaces
  • 2-aisle, automated small-parts warehouse for 8,120 bins
  • 12 meter high automated order consolidation buffer for production and dispatch
  • SAP EWM supported by the material flow control of Klinkhammer including storage space management

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Hauff-Technik is one of Europe’s leading companies in the field of building entries, including sealing systems for cables, pipes and house entries, to protect buildings – from single-family homes to power plants – from the penetration of water, gas, fire, dirt and vermin.

The Requirements
A forward-looking, flexible and expandable logistics concept should be developed to move away from manual warehousing with narrow-aisle forklifts towards full automation according to the “goods-to-person principle”. A new logistics center with fully automated pallet high-bay warehouse, bin warehouse and order consolidation buffer streamlines material flows and halves throughput times. Large and small parts are stored in a space-saving manner, picked efficiently and quickly and packed with optimized shipping costs.

The Solution
The automated order consolidation buffer supplying production and packing stations is the heart of the new logistics center. All order items of a customer order are consolidated there and, together with the corresponding pallet goods, supplied time-synchronized from the high-bay warehouse to the packing stations.

Reference Sheet (PDF)

Data and Facts

  • 2-aisle, fivefold-deep, 27 meter high, automated channel warehouse with 13,200 pallet storage locations in silo construction
  • 7-aisle, double-deep, automated small-parts warehouse with 31,920 bin storage locations (bin footprint 600 x 400 mm and 800 x 600 mm)
  • Lateral flow channels in the small-parts warehouse as order consolidation buffer
  • 5 order picking workstations for multi-order picking and a storage station
  • Conveyor connection to the packing stations
  • Warehouse management via SAP EWM

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Simba Dickie Group

Simba Dickie Group, one of the leading toy manufacturers, employs about 3,000 people at 30 locations worldwide. The product portfolio of Simba Dickie Group consists of more than 4,000 toy products of more than 20 brands, such as Smoby, BIG, Eichhorn, Majorette, Aquaplay, Schuco and Noris.

The Requirements
At the location in Sonneberg, the storage capacity should be bundled centrally in order to be able to do without external warehouses to a large extent. The aim was to compact the warehouse and increase the storage capacity. Large and small parts should be stored in a space-saving manner, picked efficiently and quickly and packed with optimized shipping costs.

The Solution
A 3-aisle, automated small-parts warehouse was extended by 4 aisles and equipped with modern picking workstations for ergonomic multi-order picking of 8 orders simultaneously. The storage and retrieval performance of 600 double cycles per hour enables high picking performance and fast processes. A fivefold-deep automated high-bay warehouse offers compact, space-saving storage of pallets.

Reference Sheet (Pdf)

Data and Facts

  • Silo-type warehouse - 5,676 pallet storage locations with 82 order picking lanes
  • Fully-automated storage and retrieval crane with double "Muli" satellite vehicles
  • Manual warehouse: 9,500 pallet storage locations
  • Reach truck, palletizing robot, automatic pallet stretch wrappers
  • Klinkhammer Warehouse Management System with SAP-Interface
  • Production: ~ 500 cardboard boxes/h
  • Palletizing: 30-50 pallets/h
  • B/C-warehouse: 30 pallets/h
  • Storage/retrieval A-warehouse: 40 pallets/h
  • Order picking: 3,000 positions/day

Big Toys

The Customer
BIG-Toys is a company of the Simba-Dickie Group, which sells toys globally and is one of the Top Five in the toy sector. Major brands are, for example, BIG (Bobby Car), Eichhorn, Schuco or HEROS. 2000 Big BOBBY-CARS leave the line every day in Big-Toys, which are delivered to wholesalers and retailers worldwide

The Requirements
The Klinkhammer Group was responsible for planning and realizing the complete intralogistics. The flow of goods comprises the various production and assembly areas – from blow forming and injection molding, to supplying the assembly lines with all necessary components from the semi-finished goods store, to palletizing robots and automatic pallet stretch wrappers, to storing the finished products in the high-bay warehouse – as well as retrieval and picking of customer orders.

The Solution
Thanks to the use of radio frequency for data transmission all material flow transactions are linked. The heart of the solution is an around 30 meters high silo-type warehouse featuring a capacity of 5,700 pallet storage locations and fully automated “satellite vehicle” stacker crane used for crosswise storage (multiple load handling device, ten pallets deep storage) which ensures storage and retrieval of finished A-goods and fast-moving articles and the supply of goods to 90 order picking lanes. At these picking lanes, individual cartons are picked. Another 9,500 pallet storage locations are available in two manual pallet racking systems where pallets are stored and retrieved by means of high reach trucks. Via the SAP-interface, master data, storage data and order data are received. Same applies to production orders which contain bills of material and are prepared for delivery to production. For this, a production module was integrated in the Klinkhammer WMS. Via conveyors, the production delivers the goods directly to a palletizing robot. Following the automatic load securing, the goods reach the shipping center in the neighbouring building via a conveyor tunnel. Picking orders are broken down to packaging units (order splitting). Hence, a position may consist of pallets, individual cartons and individual pieces and then be processed in an order-related manner or in parallel in several zones. A spacious consolidation zone in the shipping area is used for merging the goods that belong to one order. 

Data and Facts

  • 1-aisle, double-deep, automated shuttle warehouse with 3 KlinCAT multilevel shuttles and 6,720 container storage locations

  • 1-aisle, automated pallet high-bay warehouse with 1,708 storage locations

  • 1-aisle, automated small-parts warehouse with 8,316 container storage locations

  • Flexible sectioning into up to 16 different compartments per container

  • Conveyor-bridge

  • 12 workstations for order picking, goods receipt and quality assurance

  • The warehouse management system KlinkWARE® integrates 3 automated storage areas and several manual warehouses

Göpfert - More Machinery

The Customer
Göpfert is one of the leading machine manufacturers worldwide for processing corrugated cardboard. From its company headquarters in Wiesentheid, Göpfert manages and controls all steps from development to production and assembly through to global sales.

The Requirements
More than 32,000 parts ranging from the smallest screw to a roller weighing more than 5 tons are held available in different warehouse types. In order to expand production and sales, the principle of manual warehousing needed to be fundamentally reconsidered. Increased safety, transparency and speed were the focus of the expansion of the site with new intralogistics.

The Solution
The manual processes for the assembly line and spare parts supply were replaced by an automated, compact warehouse and paperless order picking. The new automation solution combines a container and pallet warehouse including pre-zone and order picking workstations thus ensuring a smooth and optimized flow of materials. In a second stage of expansion, the system was extended by a high-performance multilevel shuttle warehouse with three KlinCATs and a conveyor bridge connecting the shuttle warehouse with the existing system and the order picking and goods receipt workstations. Besides the automated storage areas, the warehouse management system KlinkWARE® integrates several lift storage areas, a manual high-bay warehouse, three block storage areas, a shelf storage, a cantilever storage and a crossdocking block storage. 8 assembly line storage areas and 15 pre-assembly workstations are connected to the warehouse.

Advantages for the Customer
High and continuous transparency, faster processes in the goods receipt and shipping area and minimization of the error rate are significant advantages. Thanks to the intelligent material flow concept, the networked software and the new automation solution, Göpfert is one step ahead of its competitors also in terms of intralogistics.

Reference Sheet (PDF)

Data and Facts

  • Silo-type high-bay warehouse (11,600 pallets and 4,600 containers)
  • Pick-by-light order picking platform for 18 source pallets and multi-order picking for 28 target pallets
  • High order picking performance of up to 250 picks/h
  • Fast moving articles are buffered in the order picking area

Rotho - Plastics industry

The Customer
Rotho Group develops, produces and distributes plastic products in the field of consumer goods, baby products, pet products and waste disposal products, ranging from plastic storage systems in the kitchen up to office organization systems.

The Requirements
Due to the continuous growth, a high performance pallet picking area equipped with pick-by-light technology and a connected automated pallet high-bay warehouse and container warehouse have been implemented at the Würenlingen location. The aim of the automatisation was to considerably shorten access times by means of a high-performance pallet order picking comprising multi-order picking and parallel order picking of containers and pallets.

The Solution
The automated silo-type high-bay warehouse with11,600 pallet storage locations and the automated small-parts warehouse with 4,600 container storage locations have been connected by conveyors to the upstream order picking and shipping areas. In a warehouse pre-zone, pallets are handed over by conveyors to a transfer vehicle with integrated support frame and are automatically made available for order picking at the buffer stations. Via pick-by-light display, the picker receives information on the quantities to be picked from the source pallets and to be packed onto the 28 order pallets on the opposite side. Thus, multi-order picking enables the picker to process several orders in parallel. The support frame of the transfer car ensures a tight stacking pattern and supports the stacking and wrapping of difficult to stack plastic articles. Subsequent to the order picking, the order pallets are automatically stretched.

The Advantages for the Customer
The pick-by-light pallet order picking, which is individually tailored to the customer requirements, ensures short access times. The operator guidance significantly minimizes picking errors and small parts picking from containers is integrated. During a pallet change, no waiting times arise.
Reference Sheet (PDF)

Data and Facts

  • Pallet high-bay warehouse: 22,884 storage locations
  • Automatic small-parts store: 15,360 containers à 600 x 400 mm


  • Pallet conveyors: 7 pallet stacker cranes with double load handling device, around 300 m of conveyors (incl. 2 lifts, 1 crossways transfer car)
  • Tote conveyors: 3 tote stacker cranes, around 1000m of conveyors


  • Material flow control (MFC) / warehouse management system (WMS)

Performance data:

  • 12 power order picking stations: 150 pos./h, 500 full cardboard boxes/h
  • 6 small-parts picking stations: 120 pos./h, 450 wallpaper rolls/h
  • 1 returned goods workstation
  • Shipping area: 20 full pallets/h and 620 individual cardboard boxes/h

Marburger Tapetenfabrik - Murals

The Customer
Marburg wallcoverings is a highly performing, mid-sized company. Wallpapers manufactured by Marburg wallcoverings reach customers in more than 80 countries all over the world. The full-line supplier offers quality wallpapers for all requirements, luxury wall coverings for an exclusive atmosphere, design objects made by artists like Ulf Moritz, Luigi Colani or Karim Rashid and technical wall coverings for industrial buildings and hotels.

The Requirements
The product range of Marburg wallcoverings comprises more than 4,000 different wall coverings. While formerly large quantities were ordered and stored by the retailers in their stores, nowadays highly flexible and customized orders are in demand. The logistic concept used so far was not able to cope with the trend toward smaller order quantities and shorter cycles.

The Solution
The responsible managers at Marburg wallcoverings opted for a fully-automated solution for both the high-bay warehouse and the small parts storage section. The pallets with the goods packed in cardboard boxes leave the production area and are then transported directly to the high-bay warehouse via a conveyor bridge. Once arrived, the goods are distributed homogeneously and stored in the warehouse fully automatically. The dual load handling devices with parallel replenishment unit guarantee maximum efficiency. When distributing the goods over the warehouse, criteria such as sales frequency or production sequence play a vital role. This data is stored in the program of the Klinkhammer warehouse management system. The logistics center at the front of the newly built high-bay warehouse is the key element of this logistic solution. Here, 12 order picking stations have been built for picking goods from cardboard boxes. At each work station the necessary picking information are provided by displays. Thanks to the cardboard boxes being clearly labelled right from the start traceability on all levels is no problem. Once delivery is ready for shipment, conveyors ensure transporting the orders to the labelling station and finally to the dispatch area. The labelling system has been certified for all large shipping companies such as Deutsche Post or UPS. Small orders, supplier samples, brochures or promotional products are retrieved from the adjacent automatic small-parts warehouse – featuring 15,360 tote storage locations – and then directed to the “picking workplaces for small quantities”. At these workstations products are repacked and automatically transported on to the next station. Deliveries containing complete orders are conveyed automatically to the i-point where they are transported by forklift trucks to the shipping zone.

The Advantages for the Customer
The fully automated solution in all zones of the warehouse increases transparency of the goods movements in the warehouse, minimizes throughput times and cuts down the time from receiving the order to goods shipment. The warehouse management software of Klinkhammer thereby provides a permanent and continuous overview of all logistic flows and access on all levels.   Reference Sheet (PDF)

Data and Facts

  • 3-aisle automatic tray warehouse (8,400 storage locations)
  • 3 automatic storage and retrieval cranes with drawing technology
  • Special conveyor technology in special chain design for weights up to 150 kg per tray
  • Pre-zone loop with a performance of 400 trays/h and picking zone with 4 work stations
  • Direct connection of the Klinkhammer system control to SAP WM / LES

Niehoff - Tray Warehouse

The customer
Maschinenfabrik Niehoff is one of the world's leading suppliers of wire drawing machines and drawing lines for the wire and cable industry. More than 700 employees work at the headquarters in Schwabach (close to Nuremberg / Germany) or in one of the ten locations on three continents. For more than six decades, Niehoff has been offering cuttingedge technology for the wire and cable industry.

The requirements
In order to cope with future growth, a multistage construction project for a new production and logistics location in Schwabach was realized. The logistical core consists of an automatic tray warehouse with about 8,400 storage locations. The aim was to increase the storage density using tray technology, the reduction of throughput times and a significant performance increase.

The solution
The three-aisle automatic tray warehouse including pre-zone platform and conveyor loop is designed for 8,400 trays. It offers high flexibility when storing packages of different sizes and heights. The tray warehouse is optimized for three different container heights and is supplied by three highly dynamic automatic storage and retrieval cranes (AS/RS), which are equipped with a special towing device for load handling. Components produced or bought from outside order-related for the production of the NIEHOFF machines are stored here. Steel trays with a sheet thickness of 2 mm ensure the stability of the load carrier when carrying weights of up to 150 kg per tray. A special conveyor technology in special chain design with integrated rubber pads ensures a gentle and low-noise transport of the heavy trays. The pre-zone loop has a performance of 400 trays/h. Four ergonomically designed receiving and order picking stations in the pre-zone of the high-bay warehouse ensure a smooth processing of all small parts orders. They are equipped with scanners, height and overweight controls. The system is controlled by the software of Klinkhammer which is directly connected to the SAP system. The visualization system of Klinkhammer illustrates the material flows.

Advantages for the customer
The three-aisle tray warehouse is a further step to even more efficiency and high storage density in the logistics of NIEHOFF. It is the aim to further improve the quality and increase the profitability of logistics. To achieve this aim, goods receiving, storage and retrieval of goods, order picking and production are connected by state of-the-art conveyor and storage technology.

Reference Sheet (Pdf)


Data and Facts

  • 2-aisle Tray warehouse (automatic small parts warehouse), 1595 trays
  • Up to 16 types of containers of different sizes per tray
  • Manual pallet warehouse (1,000 storage locations) with narrow forklift trucks and radio data transmission
  • Retrofit of system control (retrieval crane and conveyors)

Gerhard Mosca AG - Strapping Systems

The Customer
The company Mosca located in Waldbrunn is one of the leading manufacturers of strapping systems.

The Requirements
A tray warehouse (automatic small parts warehouse) was erected in the existing, very low storage rooms. Up to 16 types of containers of different sizes (for small parts; grid-type load handling device) can be stored on one trayof 1230 x 820 mm . This allows greatest possible flexibility as to the efficient use of storage space.

The Solution
A manual pallet warehouse with around 1,000 storage locations was created for the storage and handling of bulky goods. The receipt of goods for the automatic small parts warehouse occurs in the pre-zone of the warehouse, at a work station with integrated scales. Narrow forklift trucks and radio data transmission guarantee the handling of goods in the pallet warehouse. The article master data define whether the goods enter the automatic small parts warehouse or the manual pallet warehouse. The manual warehouse is operated via radio data transmission using forklift truck terminals and MDE. Order picking takes place according to the man-to-goods principle. Order picking in the automatic small parts warehouse is done at 3 picking stations.

The Advantages for the Customer
A carriage transports the goods to and away from the picking stations depending on the order type. This is important as orders are divided into order groups which are processed by specialized staff members. After picking has been completed, a consolidation takes place with the goods coming from the manual area. Additionally, the automatic small parts warehouse is linked to a KANBAN system which was implemented to automate the supply of consumables to production.

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