New building and extension of high-bay warehouse as well as new raw material warehouse at Liebensteiner Kartonagen

The Liebensteiner Kartonagenwerk processes corrugated board formats into finished packaging and has made an outstanding name for itself with individual packaging solutions. The family-owned company offers a wide range of products from attractively printed consumer goods packaging to heavy goods and transport packaging. At its site in Plößberg, HÖRMANN Logistik maximised its storage capacity with a new high-bay warehouse and its expansion in a second construction phase. A new raw materials warehouse was also built. Liebensteiner is a pioneer in the corrugated board industry with this state-of-the-art and fully automated warehouse.

Concept

HÖRMANN Logistik took the specific properties of corrugated board into account for the innovative warehouse concept. These are essentially weight and volume. Relatively large volume means that a large number of pallets are produced during production. The relatively low weight, in turn, allows the simultaneous transport of several load units during storage and retrieval. Depending on the pallet size, one to three pallets can be transported simultaneously per storage and retrieval machine (SRM) trip and stored or retrieved with a play of the load handling device. A technology that increases the performance of the stacker crane by almost three times compared to a conventional stacker crane. This immense device performance makes it possible to effectively cover long distances and thus to create large storage capacities through an extremely long high-bay warehouse. The 5-aisle high-bay warehouse is equipped with five fully automatic storage and retrieval machines. It simultaneously supplies the production, accepts finished goods from the production and retrieves finished goods from the shipping area within a specific time window and at the exact unloading point. With the extension of the high-bay warehouse, almost 20,000 additional storage spaces could be gained with the same number of storage and retrieval units. The control and management of the complete system is carried out by the HÖRMANN intra Logistics System HiLIS, which communicates via interface with the Liebensteiner HOST system. According to sophisticated storage strategies, HiLIS calculates the storage location in order to achieve an optimum of short travel times for the SRM, a weight distribution to all aisles and a high degree of warehouse utilization. The HiLIS system visualization supports operation and control of the entire system with simple, ergonomically designed masks in real time. The logistical masterpiece is to fill the dispatch routes for a truck in such a way that the material flows from all warehouses converge there almost synchronously.

Highlights

New building and extension of high-bay warehouse

•     5-aisle high-bay warehouse: 186 or 273 x 46 x 33 m (L x W x H)
•     14 levels with up to 36,000 or 52,000 parking spaces
•     5 storage and retrieval machines in single mast design
•     Flexible, up to triple-deep storage of pallets of different sizes
•     Maximum flexibility with regard to the storage of different load unit sizes with up to three sub-pallets and palletless
•     Use of roller and plastic chain conveyors for gentle pallet transport
•     Retrofit of the existing high-bay warehouse and the existing shipping hall with connection to the new areas
•     Max. size of the loading units 2,800 x 2,200 mm with up to three sub-pallets
•     Single, pair and triple transport
•     Installation of a new warehouse management system with integration of the existing plant components

New high-bay warehouse for raw materials

•     3-aisle high-bay warehouse: 97 x 25 x 13 m (L x W x H)
•     Max. charge dimensions: 3.05 x 2.5 x 1.9 m (L x W x H)
•     Max. load weight: 2 t
•     3 storage and retrieval machines with 8 telescopic forks each
•     Storage/retrieval capacity: 79 LE/h
•     High storage capacity with small footprint
•     Flexible assignment of the shelf compartments
•     Transport and storage without underpallet and load securing
•     Just-in-time delivery for processing
•     Storage capacity up to 1.5 million m²

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