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Turnkey Automation in the Corrugated Cardboard Warehouse
The practical guide for corrugated cardboard manufacturers who want to manage production and intralogistics from a single source—from the corrugator to the loading dock.
Conveyor technology, warehouse technology, and control software from three different providers—that was long the standard in the corrugated cardboard industry. Anyone who wants to remain competitive today needs an end-to-end solution. This guide shows how integrated turnkey systems make handling a variety of formats manageable, increase corrugator utilization, and ensure delivery reliability.
Checklists
In this guide, you’ll learn through practical “listicles” whether your current corrugated cardboard logistics setup is ready for automation
- 5 Key Takeaways on Corrugated Cardboard Intralogistics from a Single Source
- When Does Automation Pay Off? ROI Calculation, Operating Costs, Payback Periods, and Minimum/Maximum Structural Requirements and Options
- Checklist: Is your plant ready? 10 questions for self-assessment
If you find yourself nodding in agreement on several points: This guide shows you where to start.
What to Expect
Four chapters with practical planning guidelines for operations managers and logistics managers:
- Current Situation
- Why Forklift Logistics in Corrugated Cardboard Plants Is Reaching Its Economic Limits Today
General Contractor Approach - How a general contractor provides material handling systems, warehousing, and software all from a single source
Reference Projects - Alzenau Corrugated Board (Palm Group) and Liebenstein Cardboard Plant with Key Figures
Cost-Effectiveness ROI Assessment, Decision Matrix, and Self-Assessment: Is Your Plant Ready for Automation?
Download Guide: Turnkey Automation in a Corrugated Cardboard Warehouse
What This Guide Offers You
- Increase corrugator utilization: Boost WPA productivity by up to 50%
- Eliminate external warehouses: Manage up to 41,800 storage locations fully automatically
- Reduce labor costs: Fully automate forklift traffic between production and the loading dock
- Avoid system disconnects: Control conveyor systems, high-bay warehouses, and WMS via a single software platform
- Investment security: Reference projects with real ROI metrics and a decision matrix
Turnkey Corrugated Cardboard Intralogistics – Real-World Examples
We have already had the opportunity to implement new facilities with significantly fewer system disconnects for these major players in the corrugated cardboard industry:
State-of-the-art fresh food logistics meets Hundertwasser design
Refrigerated high-bay warehouse Andechser Molkerei
When fresh produce logistics meets innovative architecture: at Andechser Molkerei Scheitz GmbH, HÖRMANN Intralogistics has implemented a highly dynamic cold storage system that is not only functionally impressive, but also visually stunning. The 2-aisle high-bay warehouse in characteristic Hundertwasser architecture combines state-of-the-art automation technology with sustainable refrigerated storage for 3,900 pallet spaces.
The concept
Dairy products require perfect storage conditions and absolute adherence to deadlines. For Andechs, we developed a complete solution that combines maximum dynamics with precise MHD management. The centerpiece is a double-deep high-bay warehouse in silo design, supplemented by intelligent picking areas and sequenced dispatch provision. We seamlessly integrated all operational areas - from production to shipping.
Objectives and challenges of the project:
- Optimal storage of temperature-sensitive dairy products at a constant 4°C - Maximum dynamics for fast goods turnover and short best-before-date cycles
- Efficient space utilization through double-deep storage on a compact footprint
- Automated picking with maximum picking accuracy
- Complete system integration of all production and logistics areas
- Architectural integration into the unmistakable company design
The solution in detail
The automated cold storage system is based on a 2-aisle high-bay warehouse measuring 81 x 15 x 18 m. Two storage and retrieval machines in a two-mast design, each equipped with telescopic double forks, ensure a storage and retrieval capacity of 96 pallets per hour.
The double-deep storage maximizes the capacity to 3,900 pallet spaces. An automated picking area for 74 main items is fed directly from the high-bay warehouse, while a manual area covers 227 additional items. Pick-by-voice technology ensures error-free picking.
The HiLIS Warehouse Management System orchestrates all processes and ensures optimum MHD rotation. Automatic conveyor and distribution systems connect production, goods receipt, pallet inspection station, picking and dispatch provision to create a continuous material flow.
Facts & figures
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About the customer:
Andechser Molkerei Scheitz GmbH was founded in 1908 and is now Germany's largest organic dairy under the management of Barbara Scheitz. Based in Andechs-Erling near Munich, the traditional family business exclusively processes organic milk from more than 630 farmers from controlled organic animal husbandry. As a pioneer of the organic movement, Andechser develops and produces high-quality dairy products such as yogurt, cheese, quark and UHT milk. The company stands for regional added value, sustainable agriculture and the highest quality standards for organic food.
Contact us
Do you recognize yourself in the Andechser Molkerei story with challenges and possible solutions for your own business? Get in touch with 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.
High-bay warehouse
Continental Novi Sad High-Bay Warehouse: 22,000 storage locations for innovative display systems
State-of-the-art intralogistics for innovative display solutions: HÖRMANN Intralogistics is implementing a highly automated, 9-aisle high-bay warehouse with 22,000 storage locations for digital dashboards at Continental’s facility in Novi Sad. A tailor-made solution that perfectly combines flexibility and efficiency.
The Concept
For the Serbian production site of the German technology company Continental, we developed an innovative warehouse concept that meets the specific requirements of the automotive industry. The system combines the highest level of flexibility in pallet storage with maximum efficiency in material flow—perfectly tailored to the international demand for Continental’s cutting-edge technological solutions for display systems.
Project Goals and Challenges:
- Capacity Expansion: Optimization of warehouse logistics to meet growing international demand
- Size flexibility: Storage of different pallet sizes (Euro and special oversized pallets)
- High performance: Up to 522 putaways and retrievals per hour
- Automation: Efficient, fully automated warehousing during ongoing operations
- Integration: Seamless integration with existing production processes
The Solution in Detail
The 9-aisle high-bay warehouse, built in a silo design, offers double-depth, size-flexible cross-storage across two floors. Nine state-of-the-art storage and retrieval machines ensure precise material flow movements, while two separate electric floor conveyor systems optimize putaway and retrieval. The HiLIS Warehouse Control Software intelligently manages all processes and provides complete transparency across all warehouse areas through system visualization.
Facts & Figures
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“HÖRMANN Intralogistics’ custom concept won us over with its maximum flexibility and adaptability to specific loading units, as well as its high volume of incoming and outgoing goods. The automated warehouse system is another key component at the Novi Sad site.”
– Tamara Fischer, Logistics Subproject Manager, Novi Sad, Continental
About the Customer:
Continental develops groundbreaking technologies for sustainable and connected mobility. Founded in 1871, the technology company generated revenue of 41.4 billion euros in 2023 and employs approximately 200,000 people in 56 countries. The Novi Sad site comprises development, research, and production facilities for innovative display solutions covering 30,000 m².
Watch the reference video "Drone Video: High-Bay Warehouse"
Contact Us
Do you see yourself in Continental AG’s story, which highlights 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.
The world's leading manufacturer of machines for plastics and rubber processing has equipped its new production plant in Parsdorf near Munich with a state-of-the-art storage system. HÖRMANN Intralogistics implemented an end-to-end automation solution that efficiently manages both small parts and pallets. The project comprises 40,000 storage locations and shows how intelligent intralogistics successfully combines growth and efficiency.
The concept
HÖRMANN Intralogistics worked with an SAP/EWM partner to develop an integrated intralogistics solution to restructure the entire material flow at the new KraussMaffei plant in Parsdorf. The concept combines automated warehouse and conveyor technology with intelligent warehouse management to create an end-to-end system.
Objectives and challenges of the project:
Primary objective:
- Efficient organization of incoming and outgoing goods to meet the growing demand in the plastics and rubber processing sector
Central challenges:
- Complex project implementation during the pandemic years with a difficult supply chain situation
- Integration of different warehouse types for different product categories
- Seamless connection to existing SAP system landscape
- Optimization of picking processes for large and small parts
The solution in detail
Two-tier warehouse strategy The system combines a small parts warehouse for precise picking with a pallet warehouse for large-volume goods. Both areas are networked with each other using intelligent conveyor technology from KLATT.
Control and integration The HiLIS control technology with system visualization orchestrates all material flows. Seamless SAP/EWM integration enables consistent goods tracking and optimum inventory management.
Flexible workstations Combined picking stations process both large and small parts efficiently. A tower storage system for sequencing supports order-related compilation and reduces throughput times.
Facts & figures
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About the customer:
KraussMaffei Technologies is the world's leading manufacturer of machines and systems for plastics and rubber processing. As a "Pioneering Plastics" company, the company develops innovative solutions for the growing requirements of the industry and has established its new plant in Parsdorf near Munich as a modern production site.
Watch the reference film "Insider Tour
Contact us
Do you recognize yourself in the story of KraussMaffei GmbH with challenges and possible solutions for your own company? 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.
Intralogistics for chilled food
HÖRMANN: AutoStore® and multi-order picking for cheese specialties
HÖRMANN Intralogistics implemented an AutoStore® system with multi-order picking for Heiderbeck GmbH in an existing refrigerated warehouse. The Bavarian sales company for cheese specialties uses the system for efficient picking of its high-quality products.
The concept
Heiderbeck GmbH needed an intralogistics solution that would meet the special requirements of chilled cheese specialties. HÖRMANN Intralogistics developed a customized AutoStore® system that was integrated into an existing refrigerated warehouse. At its heart is a two-stage single-double grid with multi-order picking and food-compliant container cleaning. The picked products are seamlessly forwarded to palletizing via connected conveyor technology.
Objectives and challenges of the project:
- Temperature consistency: Continuous cooling of the sensitive specialty cheeses throughout storage
- Increased efficiency: Optimizing picking performance through multi-order picking processes
- Hygiene requirements: Food-compliant container cleaning in accordance with legal requirements
- Space optimization: Maximum storage capacity in the existing hall space
- Process integration: Seamless connection to downstream packaging and shipping processes
- Scalability: Option to expand the system as required
The solution in detail
The AutoStore® system with 51 Red Line robots operates on a single double grid for 15,700 bin locations. At five multi-order picking ports, employees pick several customer orders in parallel using put-to-light technology and stationary barcode scanners.
Nine carousel ports and three conveyor ports enable flexible storage and retrieval. Two transfer cells ensure food-compliant container cleaning. The HiLIS AS Warehouse Management System controls all processes and is directly connected to the customer HOST.
Facts & key figures
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About the customer:
Heiderbeck GmbH, based in Olching, Bavaria, is an established distribution company for high-quality cheese specialties and chilled delicatessen products. The company successfully supplies the German market with selected delicatessen products and relies on the highest quality standards for the storage and distribution of its temperature-sensitive product range.
Watch reference movie
Contact us
Do you recognize yourself in the story of Heiderbeck GmbH with challenges and possible solutions for your own company? 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.
