Reference AutoStore
World's first combined chilled and ambient temperature AutoStore® system for online retailer flaschenpost SE
Industry first: HÖRMANN Intralogistics has implemented innovative micro-fulfilment solutions for flaschenpost SE with combined chilled and ambient temperature AutoStore® systems. The systems in Langenfeld and Cologne set new standards in automated eGrocery logistics with intelligent combined workstations.
Fast delivery needs smart logistics
As a growing online supermarket with the promise of "delivery within 120 minutes", flaschenpost SE faces particular logistical challenges: The extensive expansion of the product range to include food and the rapidly growing demand require highly efficient intralogistics. Over 30 warehouse locations supply more than 200 cities in Germany with beverages, food and everyday products.
HÖRMANN Intralogistics has developed a globally unique solution for this: AutoStore® systems for different temperature zones are brought together at specially developed combined work stations. Staff pick chilled and non-chilled goods in parallel for one order. The successful pilot system in Langenfeld was followed by the commissioning of the second system for Cologne - the 50th AutoStore® project from HÖRMANN Intralogistics.
The concept
The heart of the solution is the intelligent combination of two AutoStore® systems with different temperature ranges at specially developed combined work stations. The "Chilled" system for refridgerated goods operates at a constant 2°C in a fully enclosed environment. Directly adjacent is the "Ambient" system for items at room temperature.
In both temperature zones, AutoStore containers are stacked on 16 levels in the grid system. Red-Line robots move tirelessly on the rail system and supply the ports for storage and picking.
The combined workstation: where both worlds meet
The two temperature zones come together at each combined workstation: The dry goods from the ambient system arrive at the carousel port, while the chilled goods from the chilled area arrive at the specially insulated conveyor port. Staff pick from both ports in parallel into the flaschenpost containers on the in-and-out conveyor system at the workstation, which transports the picked orders to the delivery vehicles
The solution in detail
HÖRMANN Intralogistics supplied complete systems from a single source for both locations: from planning and AutoStore® installation with all robots and ports to the complete housing and cooling technology for the chilled systems. The combined workstations were specially developed to meet the requirements of simultaneous picking from both temperature zones and enable efficient handover to the flaschenpost delivery drivers.
The systems are designed for operating times of 16 hours, 6 days a week and offer growth potential in terms of both performance and storage capacity. The configuration of both systems is based on extensive simulations and takes into account the specific requirements of the respective locations.
This advanced architecture for automated eGrocery distribution centers is the result of an intensive project planning phase and trusting cooperation between HÖRMANN Intralogistics and flaschenpost SE.
Project goals and challenges:
Automation for growing requirements
The key challenge was to efficiently manage demand spike and expanded food range with automated technology without jeopardizing the 120-minute delivery advertised to customers.
World-wide innovation in temperature zones
The different temperature requirements of fresh and dry goods had to be married in one integrated system. The solution combines maximum energy efficiency with minimal cooling losses and still enables flexible, parallel picking at specially developed combined work stations with insulated conveyor ports for chilled goods and carousel ports for dry goods.
Facts & key figures
Facts
- Chilled system: approx. 8.500 containers, 18 Red-Line robots, 8 conveyor ports, grid size approx. 10 m x 40 m
- Ambient system: approx. 10.000 containers, 25 Red-Line robots, 8 carousel ports, grid size 8 m x 40 m
- Performance: approx. 1,000 container deliveries per hour, up to 12,000 item transfers per day
- Conveyor technology: approx. 100 m of connecting container conveyor technology
- Special feature: pilot project in existing property
| Langenfeld site: | Cologne site: | Both systems: |
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"The extensive expansion of our product range to include food and growing demand required further development of our intralogistics processes, employing automation technology. The cooperation with Hörmann Intralogistics in the design and detailed planning of the innovative solution, which was tailored to our needs, was very smooth and trusting."
André Damkowski
Senior Logistics Engineer at flaschenpost SE
Picture gallery
About flaschenpost
The online supermarket flaschenpost SE delivers food, drinks and everyday products to more than 200 cities in Germany. With the promise of "delivery within 120 minutes", the company has established itself as a leading fast delivery service. Over 20,000 employees ensure that customers receive their orders quickly and reliably from more than 30 warehouse locations.
Contact us
Do you recognize yourself in the flaschenpost story with challenges and possible solutions for your own business? Feel free to contact our project planning experts without obligation. We will give you an assessment of your current and optimized material flow, automation options and an initial target price.
Reference Hoval
Hoval: Fully automated storage system for heat pump production in Istebné
Hoval is one of the world's leading providers of heating and indoor climate solutions. In order to meet the sharp rise in demand for heat pumps, the company has expanded its site in Istebné, Slovakia - with a state-of-the-art, fully automated warehouse system that was planned and implemented by HÖRMANN Intralogistics as general contractor.
The project marks an important step in Hoval's strategic development. The plant was successfully accepted and handed over in August 2025. Hoval is thus creating the basis for optimizing production and logistics processes in the long term and further expanding global sales of its heat pumps.
Installing the AutoStore® system
Construction of the high-bay warehouse
Assembly of storage and retrieval machines and conveyor technology
System activation
Handover and training
Installation of the AutoStore® system
Construction of the grid and connection to the HiLIS warehouse management system - with consideration of subsequent integration into the HBW, production and conveyor technology.
Construction of the high-bay warehouse
Construction of the steel racking structure in silo design with roof and wall cladding and sprinkler system
Assembly of the storage and retrieval machines and conveyor technology
Precise coordination of all suppliers by HÖRMANN Intralogistics, including complex coordination such as the assembly of the guide rails.
System activation
Test runs and setup of the system control, commissioning of the intelligent WMS HiLIS for the interaction of all components.
Handover and training
Check of key performance indicators, final tests and intensive employee training. Customer service then takes over support during ongoing operations.
The concept
Automated multi-solution storage system with pallet high-bay warehouse, AutoStore® and HiLIS WMS
The facility combines two systems for large and small parts logistics. At its heart is a three-aisle pallet high-bay warehouse with a length of 115 meters, a width of 22 meters and a height of 40 meters. Three storage and retrieval machines with double-deep telescopic forks move the pallets fully automatically.
An AutoStore® system, which was specially designed for small parts logistics, operates in parallel. The two systems are connected via a high-performance pallet conveyor system that links incoming goods, production, order picking, finished goods storage and dispatch.
The HiLIS warehouse management system from HÖRMANN synchronizes all components and ensures seamless material flows between AutoStore®, high-bay warehouse and connected processes.
Objectives and challenges of the project:
The aim was to automate and standardize all storage and picking processes to enable Hoval to achieve greater efficiency and flexibility in heat pump production.
One challenge lay in the tight schedules and changing framework conditions, which required a high degree of precision and coordination between the trades. The interaction of the systems - AutoStore®, HRL, conveyor technology and software - also had to be perfectly coordinated to ensure smooth commissioning.
Facts & figures
| High-bay warehouse & complete system | AutoStore |
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"HÖRMANN Intralogistics impressed us during the tendering phase with its complete package for this future-oriented project. With this new solution, we can perfectly coordinate our production and logistics processes and are more than ready for the increasing demand in the heat pump market."
Dr. Vadim Tcharnetsky
Head of Indirect Procurement, Hoval Group
About Hoval
Hoval is a leading international manufacturer of heating and indoor climate solutions. With over 75 years of experience and a family-oriented corporate culture, Hoval combines innovation with responsibility for energy and the environment. The company's solutions stand for maximum efficiency and sustainability.
Reference film
Tour of the Multi-Solution Warehouse with high-bay warehouse and AutoStore
Tour of the Multi-Solution Warehouse with high-bay warehouse and AutoStore
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 without obligation. We will give you an assessment of your current and optimized material flow, automation options and an initial target price.
