Retrofit Project: Cable Industry | Germany
NKT Cable: Complete Modernization of the Three-Lane Wire Warehouse
NKT GmbH & Co. KG in Cologne relies on proven partnerships and innovative technology: The automated wire warehouse, originally implemented by HÖRMANN Intralogistics in 2010, underwent a comprehensive modernization in 2025. With new RBG technology, increased load capacity, and optimized control systems, the facility is perfectly equipped to meet the challenges of the future in cable production.
The Concept
Instead of completely replacing the proven system, HÖRMANN Intralogistics developed a customized retrofit approach. The existing steel structure and the successful robotic handling concept were retained, while all critical components were replaced. This strategy enabled a cost-effective modernization without production interruptions and made optimal use of the existing infrastructure.
Project Goals and Challenges:
- Increased performance to meet growing demands
- Load capacity: Load capacity of 1,500 kg per loading unit
- Availability: Minimization of downtime through modern, low-maintenance technology
- Future-proof: Integration of the latest control technology with long-term support
- Operational continuity: Modernization without interrupting ongoing cable production
- Increased efficiency: Optimized material flow processes for higher throughput rates
The Solution in Detail
The modernization project involved the complete replacement of all three stacker cranes with the latest stacker crane technology featuring increased load capacity. The pallet conveyor system was completely overhauled and expanded to include high-performance transport carts capable of handling up to six pallets. The new HiLIS warehouse management system intelligently controls all processes, while the expanded material flow computer ensures optimal utilization.
As the original system integrator from 2010, HÖRMANN Intralogistics brought a deep understanding of the specific requirements of the cable industry. Close collaboration with NKT enabled a precise needs analysis and the development of a tailor-made solution. Of particular note is the retention of the proven robotic handling system for cable reels with diameters ranging from 450 to 760 mm, combined with the integration of state-of-the-art control technology. This long-standing partnership proved to be a decisive factor in the smooth implementation of the complex modernization.
Facts & Figures
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About the Customer:
NKT has established itself as a leading supplier of cables and cable accessories for the energy sector. The company develops and manufactures high-quality high-, medium-, and low-voltage cables as well as related accessories for energy infrastructure projects worldwide. This international focus and broad product range place special demands on intralogistics—demands that are optimally met through modernization.
Reference Films
Before-After
Material Flow Simulation
Contact Us
Do you see yourself in Nkt Cables’ story, with its challenges and potential solutions for your own business? Feel free to contact our project planning experts with no obligation. We’ll provide you with an assessment of your current and optimized material flow, automation options, and an initial price estimate.