The Pati-Versand has specialised in patisserie supplies, confectionery and baking ingredients and accessories since 2007. The extensive product range, which is expanded annually with the latest trend articles, is also available in the tailor-made online shop. Today, www.pati-versand.de is the largest provider of cake, praline and baking ingredients for private customers in the German-speaking world. At the Herzlake location, an automated small parts warehouse for the storage of baking accessories is built in a new warehouse. Hörmann Logistik convinced with its AutoStore® concept and received the order to realise the system including the HiLIS AS warehouse management system.

Concept

The AutoStore® warehouse is built in the new building with a clearance height of 5,500 mm. Goods receipts and picking can be carried out at all workstations at any time.

For the individually tailored design of the AutoStore® system for Pati dispatch, Hörmann Logistik carried out several system simulations with original data in real time during the planning phase. The net operating time is 8 hours daily, 5 days a week.

The customer parameters together with the simulation results led to a system configuration with 12 levels, 25,000 containers, 6 carousel workstations and 2 conveyor workstation modules. This enables the required 110 goods storage and 1,040 goods retrieval operations, including the approximately 10 "fast orders" per hour, to be implemented. For a possible extension, 3 or 2 additional frames for carousel or conveyor workstations are already planned.

The AutoStore® system consists of an aluminium grid system with the overall dimensions of 24.5 m x 33.3 m x 4.1 m (L x W x H) including the service platform and a cladding of MDF boards coated on one side on three sides. In the grid system, stacks of 12 containers each are placed directly on the hall floor. Above the stacks of containers is the rail system (grid) on which the 32 battery-powered, autonomous robots move. The robots cooperatively pick up containers, re-sort them and are responsible for the supply and disposal of the carousel and conveyor workstations. The maximum total weight of the 649 mm x 449 mm x 330 mm (L x W x H) containers is 35 kg with a net load of around 30 kg. To ensure the maximum weight is maintained, an overweight check is carried out during storage. The containers can be flexibly subdivided by separating inserts for the use of several articles.

The system is controlled by the HiLIS AS warehouse management and control system, which was specially designed for AutoStore®. AutoStore® "only" knows the container number in the system, but not the contents. The higher-level WMS HiLIS AS knows the content of each container, takes over the higher-level management and control of the AutoStore® system and implements the logistical processes including the interfaces to the ERP system. The easy-to-understand graphical user interface of HiLIS AS provides clear work and picking instructions via touch screen. In addition, HiLIS AS supports permanent inventory processes, empty container insertion, status dialogues, special access to the containers and much more.

The AutoStore® small parts warehouse at Pati-Versand.de in Herzlake went into operation in early 2019.

Das AutoStore®-System besteht aus einem Aluminium-Rastersystem mit den Gesamtabmessungen von 24,5 m x 33,3 m x 4,1 m (L x B x H) inkl. der Service-Bühne und einer Verkleidung aus einseitig beschichteten MDF-Platten an drei Seiten. In dem Rastersystem stehen Stapel mit jeweils 12 Behältern direkt auf dem Hallenboden. Über den Behälterstapeln ist das Fahrschienensystem (Grid) montiert, auf dem sich die 32 batteriebetriebenen, autonomen Roboter bewegen.

Die Roboter nehmen kooperativ Behälter auf, sortieren sie um und sind für die Ver- und Entsorgung der Carousel- und Conveyor-Arbeitsplätze zuständig. Das maximale Gesamtgewicht der 649 mm x 449 mm x 330 mm (L x B x H) großen Behälter beträgt 35 kg bei einer Netto-Zuladung von rund 30 kg. Zur Absicherung des Maximalgewichts findet bei der Einlagerung eine Übergewichtsprüfung statt. Die Behälter können durch Trenneinlagen flexibel für die Nutzung mehrerer Artikel unterteilt werden.

Die Steuerung der Anlage übernimmt das von HÖRMANN Intralogistics speziell für AutoStore® konzipierte Lagerverwaltungs- und –steuerungssystem HiLIS AS. AutoStore® kennt „nur“ die Behälternummer im System, nicht aber den Inhalt. Das übergeordnete LVS HiLIS AS kennt den Inhalt jedes Behälters, übernimmt die übergeordnete Verwaltung und Steuerung des AutoStore®-Systems und setzt die logistischen Prozesse inklusive der Schnittstellen zum ERP-System um. Die einfach verständliche, grafische Benutzeroberfläche von HiLIS AS stellt via Touch-Screen klare Arbeits- und Kommissionieranweisungen zur Verfügung. Zusätzlich unterstützt HiLIS AS permanente Inventurprozesse, Leerbehälter-Einbringung, Status-Dialoge, Sonderzugriff auf die Behälter und vieles mehr.

Das AutoStore®-Kleinteilelager bei Pati-Versand.de in Herzlake ging Anfang 2019 in Betrieb.

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Giesswein Walkwaren AG is a Tyrolean family business in its third generation. From hand-picked wool in traditional quality, modern, sustainable and functional clothing and shoes are produced in our own production facilities. With special know-how and a holistic approach, the company has developed into Europe's leading manufacturer of clothing made of 100% new wool. At the Brixlegg site, a finished goods warehouse was built in an existing warehouse to support the constantly growing online shop business and stationary trade. The tailor-made concept with the modern, versatile AutoStore® system was developed by Hörmann Logistik.

Concept

Joint planning discussions and several system simulations with real data led to the individual AutoStore® system configuration with 31 robots and 17,500 containers on nine levels. The height of the AutoStore® grid was determined by the 4.6-metre high existing hall.

In order to guarantee the performance specifications of 140 storage and 900 retrieval operations per hour, 5 carousel and 3 conveyor workstation modules were initially provided. A further carousel workstation module has already been preconfigured.  The single-double grid with the overall dimensions of 26.1 x 30.4 x 3.1 m (L x W x H) is clad on two sides.

The 17,500 containers in the standard format 649 mm x 449 mm x 330 mm (L x W x H) each allow a load capacity of approx. 30 kg.

31 robots supply the Carousel workstations 8 hours a day. This requires a charging process per robot of approx. 4 hours per day, for which a total of 24 charging stations are provided at the edge of the grid.

Maximum flexibility and efficiency

In principle, all workstations are equipped so that goods receipts or picking can be carried out there at any time. The incoming goods are delivered to the workstation by the warehouse staff.

In the grid system, stacks of 9 containers each are placed directly on the hall floor. A single-double-grid rail system is mounted above the stacks of containers, on which the battery-powered, autonomous robots travel. They pick up containers cooperatively, re-sort them as required and serve them at the carousel ports. The containers can be flexibly subdivided by means of separating inserts for the use of several articles.

The AutoStore® system at Giesswein Walkwaren in Brixlegg was put into operation in July 2020.

"The new AutoStore system makes our picking processes much more effective and makes our employees' work easier. A benefit for the whole team."

Markus Giesswein

Owner

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