HÖRMANN Dealticker: Automated high-bay warehouse for raw parts at MAGNA Exteriors in Meerane

Munich / Meerane, October 2026 – HÖRMANN Intralogistics Solutions GmbH has been awarded a contract by MAGNA Exteriors (Meerane) GmbH to build a fully automated high-bay warehouse for injection-molded raw parts. A three-aisle work-in-progress warehouse is being built at the Werdauer Allee site in Meerane, which will serve as a buffer between the injection molding production line and the paint shop. Front and rear bumpers will be stored on two types of special load carriers, each with a gross weight of 90 kilograms.

The new high-bay warehouse offers 1,500 storage locations in double-depth transverse storage and reaches a height of 8.5 meters within the existing production hall. Three 2-mast stacker cranes with double-depth telescopic forks move up to 150 load units per hour out of the warehouse. The putaway capacity is 80 containers per hour. This reliably meets the required throughput for 24/7 operation.

The system closes the material cycle through fully automated delivery of empty containers. Empty special load carriers are either returned from the retrieval aisle at the paint shop or provided from the high-bay warehouse, which also serves as a storage area for empty and partially used containers. The load status and item type are detected using RFID technology, which ensures seamless traceability and error-free assignment.

The conveyor system connects the injection molding and painting facilities across up to three levels to maximize the concentration of material flow within the same floor space. Vertical conveyors, accumulation roller conveyors, and timing belt conveyors ensure smooth operation. Eleven contour checks at critical points ensure quality throughout the entire process chain. Telescoping loading stations in the injection molding area improve ergonomics for employees.

The new warehouse is seamlessly integrated into the existing HiLIS warehouse management system, which already controls an earlier project at MAGNA. The functional implementation is based on the familiar HiLIS version, allowing employees to rely on processes they are already familiar with. Integration is achieved via ERP interfaces and a central material flow control system.

In addition to storage and retrieval machines, conveyor technology, and software integration, the scope of delivery also includes the complete steel racking structure with a maintenance platform, safety fences, and access doors. As the general contractor, HÖRMANN assumes overall responsibility, from project management through installation and commissioning to operational support. A 98 percent availability rate is guaranteed.

Construction is scheduled to begin in March 2027. The first construction phase will go into operation in July 2027, followed by the second phase in October 2027.

“The new high-bay warehouse for raw parts allows us to handle a significantly wider variety of products than our previous large-load-carrier warehouse,” explains Kai Grunert, Team Leader of Industrial Engineering at MAGNA Exteriors (Meerane) GmbH. “This gives us the flexibility we need to meet future requirements.”

For MAGNA Exteriors, this is already the second project with HÖRMANN Intralogistics at the Meerane site. The first three-aisle interim storage facility for painted parts, which serves as a buffer between the paint shop and production, is already in successful operation.

About MAGNA Exteriors (Meerane) GmbH

MAGNA Exteriors (Meerane) GmbH is part of the globally active MAGNA Group and specializes in the development and manufacture of high-quality automotive exterior components. At the Meerane facility, body components such as front and rear bumpers are produced and further processed for leading automakers.