Reference Hoval
Fully automated storage system for heat pump production in Istebné
Hoval is one of the leading international companies for heating and indoor climate solutions. In order to meet the enormous demand for heat pumps, they are expanding their production capacities in Slovakia with the highest level of automation
A state-of-the-art automation solution ensures the flow of stock and materials in heat pump production at Hoval's Slovakian site in Istebné. The intelligent combination of two asynchronous storage areas is a stand.-out customization: A pallet high-bay warehouse for large parts and an AutoStore system for small parts. Both systems are brought together at a combined picking workstation and controlled centrally via the HiLIS Warehouse Management System (WMS) - for seamless, consistent and efficient intralogistics.
Behind the scenes: The construction stages of the Hoval HRL & Autostore in Istebne, Slovakia
Construction stage 1: Autostore
Construction stage 2: HRL
Construction stage 3a) Storage and retrieval unit
Construction stage 3b) Conveyor technology
Construction stage 4: PLC & HiLIS launch
Construction stage 5:Handover of entire system
Stage 1: AutoStore
AutoStore, LVS/HiLIS IBN
Installation of the AutoStore® system including WMS HiLIS - subsequent connection to HBW, production and conveyor technology taken into account.
Construction stage 2: HRL
Shelf steel construction, roof + wall, sprinklers
Construction of the shelf steel construction with roof/wall cladding and sprinkler system for the 3-aisle high-bay warehouse
Construction stage 3a) Storage and retrieval unit
Installation and assembly of the storage and retrieval units. Hörmann site management synchronizes different suppliers & trades
Construction stage 3b) Conveyor technology
Installation of the conveyor technology with all components and connection to the HBW, AutoStore and picking workstations.
Stage 4: PLC & HiLIS commissioning
Activation of the system by WMS and system control. Drive elements are checked, addressing is set up via PLC, automatic operation is started. The intelligent WMS HiLIS manages the interaction of all components.
Stage 5: Handover
Training, performance tests, SOP, ramp-up phase, availability test, handover
During the handover, the system is ramped up, key performance indicators are checked and tests are carried out. Employee training concludes the commissioning process. After handover, HÖRMANN Intralogistics customer service is available 24/7.
The concept
High-bay warehouse for pallets
The three-aisle high-bay warehouse in silo design is the backbone of the large parts logistics operations. With a length of 115 m, a width of 22 m and a height of 40 m, it offers space for a large number of pallets. It is equipped with three storage and retrieval machines, each with double-deep telescopic forks. A special feature is the use of extra-wide system pallets, which serve as carriers for finished goods.
The pallet conveyor technology connects various functional areas - from incoming goods and central order picking to outgoing goods and dispatch. The maximum throughput rate is around 100 pallets per hour.
AutoStore for small parts
An AutoStore system for small parts logistics was installed in parallel. The compact cube storage system covers around 85 m² and offers space for around 3,000 containers. Storage and retrieval is fully automated using three "Red Line" robots working at three conveyor ports. The system is supplemented by a service platform with overhead crane and electric chain hoist for ergonomic picking workflows.
Objectives and challenges of the project:
- Increasing warehouse capacity to meet growing demand in the heat pump segment
- Connecting two asynchronous warehouse areas in a continuous material flow
- Optimizing order picking through combined workstations
- Reducing manual processes through robotics and conveyor technology
- Central control via the HiLIS Warehouse Management System
- Integration into existing production processes during ongoing operations
Facts & Figures
| AutoStore® warehouse | High-bay warehouse |
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"HÖRMANN Intralogistics impressed us with an all-in package for the future-oriented project in Istebné. We are happy to increase our capacities in the heat pump market with an established and tech-savvy partner."
Dr. Vadim Tcharnetsky
Head of Indirect Procurement, Hoval Group
Picture gallery
Contact us
Do you see yourself in the Hoval story with challenges and possible solutions for your own business? Feel free to contact our project planning experts for a chat. We will give you an assessment of your current and optimized material flow, automation options and an initial target price.
