Services
Retrofit – Greater Efficiency Through Modernization
Are you already using a material handling system or a high-bay warehouse?
Are the mechanical components, hardware, and software of your logistics system no longer up to date, resulting in high maintenance and downtime costs? Are you no longer able to maintain the installed software? Then your system is ready for modernization.
Benefits
- Modernization without interrupting operations
- Increased plant performance
- Increased availability
- Ensuring maintainability
- State-of-the-art system
Our retrofit services at a glance
- Analysis of retrofit needs
- Solution Design
- Modernization of the mechanical components
- Modernization of control systems and sensors
- Modernization of computer systems
- Upgrade to the latest software
- Experienced project management
We’ll bring you up to the cutting edge of technology—talk to our retrofit specialist Christian Otterbeck.
See the services in detail
Head of Retrofit / Customer Service
Christian Otterbeck
Measurable Cost-Effectiveness
Retrofit projects are 30–50% less expensive than new construction and typically pay for themselves in 2–4 years:
✓ Lower investment costs by utilizing existing structures
✓ Reduced downtime costs through preventive modernization
✓ Greater plant reliability and spare parts availability
✓ Energy savings of up to 40% through modern technology
✓ Space-saving implementation without requiring additional space
Download White Paper
Improved Performance in Existing Buildings
How to Future-Proof Your Warehouse with Targeted Modernization
Topics & Tools:
- From Existing Infrastructure to the Future—Who Should Modernize Now
- Why Legacy Systems Are Reaching Their Limits
- Modernize Instead of Rebuilding—What’s Possible in an Existing
Warehouse - Retrofit checklist for self-assessment
- Intelligent control: How modern software makes your warehouse
more efficient - Success factors from real-world experience: How to Ensure Successful Implementation
- Measurable Results and Statistics from Over 800 Completed Retrofit Projects
- Your Modernization Roadmap: Five Steps to Long-Term
Improved Warehouse Performance
Retrofit and Modernization Services in Detail
Retrofit expertise from over 800 projects
Since 1987, we have been modernizing warehouse systems without interrupting operations. Our retrofit expertise includes:
- Mechanical & Conveyor Technology: Replacement of outdated components, capacity expansions, integration of modern transport technology
- Control Technology: Migration to current PLC systems, software modernization, interface upgrades
Warehouse Management: HiLIS WMS integration for optimized material flows and transparency - Energy Efficiency: Reduction of energy consumption through modern drive technology and intelligent control
- Safety Technology: Updates to current safety standards and fire protection concepts
- One-Stop Industrial Services: From analysis to 24/7 support—everything from a single source.
Our Retrofit and Modernization Projects
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.
Brochures, white papers, logos, images
Downloads
Downloads from HÖRMANN Intralogistics
Download brochures, white papers, logos, and images quickly and easily here to learn more about our innovative logistics solutions and optimize your intralogistics.
Brochures
Image Brochure – Your General Contractor for Intralogistics
HiLIS – Integrated, Modular Warehouse Management System
Corrugated Cardboard – We're Bringing Dynamism to the Industry
Klatt Conveyors – Your innovative partner for customized conveyor solutions
White Papers & Guides
Improved Warehouse Performance
How to Future-Proof Your Warehouse with Targeted Modernization
Warehouse Logistics: A New Era of Connectivity
- How integrated systems reliably control material flow
The Human-Machine Dream Team
- Interaction in the Warehouse—Strategies and Technologies to Combat the Skilled Labor Shortage
Turnkey Automation in Corrugated Cardboard Warehouses
- How to Manage Material Flows from the Corrugated Board Plant to the Loading Dock Without System Discontinuities
Automation Potential with AutoStore in Mid-Sized Businesses
Scientific White Paper - AutoStore® ROI at a Glance
Planner Dossier Intralogistics
HÖRMANN Intralogistics as a Structured Project Partner
in the Multi-Solution Business
Download White Paper
AutoStore for Production Buffering: A Guide for Manufacturing Companies
AutoStore in Manufacturing – Reliable small parts supply directly to the production line
Are you responsible for intralogistics at a manufacturing company and looking into how AutoStore works in a production environment?
The key question isn’t whether AutoStore can handle small parts—but whether it’s cycle-timed, fully automated, and reliable enough to supply a production line directly.
That’s exactly what this guide demonstrates—read on for more details.
Is AutoStore a good fit for your project as a production buffer?
AutoStore doesn't perform equally well in every production environment—but it is a proven solution for these situations:
- Small-part supply directly at the production line, without a manual intermediate step
- Production environments with cycle-based material requirements (KLT, small load carriers)
- Locations where existing HRL and AutoStore systems must be synchronized
- Production facilities with increasing output and limited warehouse space growth
- Integration with existing ERP or MES systems is a requirement
- Greenfield projects and expansions during ongoing operations
If this sounds like you: Talk to us.
What the guide covers
AutoStore is known as a high-density small-parts warehouse for retail and logistics environments. In manufacturing, different requirements apply: The system must not only store items but also deterministically control the supply of materials to the production line—without any human intervention.
This guide answers the questions that logistics planners and plant managers ask in practice:
- When is AutoStore suitable as a production buffer—and when is it not?
- How does its operation differ from traditional small-parts applications?
- What are the requirements for the control system (HiLIS WMS), interfaces, and cycle times?
- What do completed projects demonstrate?
Download the guide:
AutoStore for Production Buffering: A Guide for Manufacturing Companies
A concise guide, tailored for decision-makers in production logistics:
- Deployment criteria: When AutoStore Is Suitable as a Production Buffer
- Technical Requirements: Interfaces, cycle times, control system integration
- Distinction: Production buffer vs. traditional small-parts warehouse
- Reference Projects: Siemens Rastatt, Christ Packing Systems
AutoStore as a Production Buffer
Two Real-World Projects
Download White Paper
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:
