Subscribe

Day: 22 November 2021

Rapid Order Processing at Very’s Automated DC

Posted on by David Priestman

Advanced automation technology from Knapp is helping The Very Group to fulfil customer orders in just 30 minutes at Skygate, its new distribution centre in the East Midlands (UK).

Launched on the day that the UK’s first lockdown was announced in March 2020, the 850,000 sq ft facility has secured a number of benefits for the online retailer and its customers, including greater product availability, faster refunds and enhanced ability to handle peak trading periods.

“A fast, seamless fulfilment operation is vital for great customer experience, and that’s what we focused on when developing Skygate’s highly automated technology,” commented Phil Hackney, Chief Operating Officer at The Very Group. “Throughout the pandemic, that technology has helped us to manage huge volumes of orders. It also enabled us to bring all of our clothing and footwear returns under one roof for the first time and means we’re well positioned for future growth.”

Despite a surge in orders during its first year as the pandemic fuelled demand for e-commerce, Skygate managed to deliver the performance required by Very. The automated picking, sortation and packaging technology from KNAPP means that orders can be ready for dispatch within 30 minutes, compared to around four hours at Very’s previous fulfilment centres. The fastest order to date, processed in July 2021, was ready for dispatch in just 17 minutes.

Operating 24/7, Skygate has processed over 40 million items since its launch and has significant potential for future expansion. The efficiency of processes at the facility, combined with the consolidation of three sites into one fulfilment and returns centre, will contribute up to £25m in efficiency savings per year for The Very Group. Skygate’s central location – close to the M1 motorway and adjacent to East Midlands Airport – combined with the on-site rail freight terminal will save Very an estimated one million road miles a year.

Designed for peaks

With Skygate responsible for the fulfilment of 95% of the Group’s customer orders, KNAPP worked closely with Very to ensure that the automation would be able to handle peak volumes with the required speed and accuracy. The logistics technology enables the pre-picking of orders on high-traffic days, which helped Very to cope with record-breaking Christmas and Black Friday trading in 2020. Sales for Very.co.uk increased by over 25% year-on-year in the seven weeks to Christmas 2020, with Skygate processing an impressive 3.9 million orders during this period, peaking at 265 orders per minute.

Key to both rapid order fulfilment and efficient returns processing at Skygate is KNAPP’s EcoPocket system. This pocket sorter technology uses a matrix sortation algorithm to arrange products in RFID-enabled pockets into the correct sequence to fulfil customer orders at the packing stations.

Items are placed in the pockets at a series of workstations, where totes of product arrive automatically from KNAPP’s OSR Shuttle Evo storage system. Taking an item from a tote, the operator scans it and drops it into a pocket with a single swipe action.

One of the largest shuttle systems in Europe, the automatic store features over 400 shuttles and provides almost 640,000 storage locations. Combined with 120,000 pockets in the EcoPocket system and 26,000 pallet locations in the manual store, Skygate houses an

One-touch returns handling

The automated handling solution at Skygate also enables one-touch processing of returns, with products available for resale within 30 minutes and customer refunds provided faster than ever before. Returns are prioritized, with two-thirds leaving the site within 24 hours and the overwhelming majority within three days.

A vast dynamic buffer of EcoPockets on the third mezzanine level of the warehouse makes returns processing a breeze and gives Skygate the capacity to handle 80,000 returned items per day.

Also featuring a dispatch sorter with 96 destination chutes, the automated logistics solution is controlled by KNAPP’s KiSoft suite of software, comprising Warehouse Management System (WMS), Warehouse Control System (WCS) and machine control systems for seamless integration.

“We are extremely proud to have developed this brand-new distribution centre from concept to reality in just three years,” commented Anton Tschurwald, Vice President Retail Solutions for KNAPP AG. “A strong spirit of partnership with the customer meant that Skygate was delivered within budget and on time, despite going live during the COVID-19 lockdown.”

To keep the complex project on schedule despite the lockdown restrictions, KNAPP worked with Very to develop – within just a week – the infrastructure and processes to continue start-up of the system by the British team with support from technicians working remotely from Austria. “The significant challenges were overcome through a potent combination of teamwork and technology,” said Tschurwald.

To ensure maximum system uptime, a 33-strong team of KNAPP Customer Service technicians is based permanently at Skygate, carrying out comprehensive preventive maintenance and dealing quickly with any issues that arise.

Rapid Order Processing at Very’s Automated DC

Posted on by David Priestman

Advanced automation technology from Knapp is helping The Very Group to fulfil customer orders in just 30 minutes at Skygate, its new distribution centre in the East Midlands (UK).

Launched on the day that the UK’s first lockdown was announced in March 2020, the 850,000 sq ft facility has secured a number of benefits for the online retailer and its customers, including greater product availability, faster refunds and enhanced ability to handle peak trading periods.

“A fast, seamless fulfilment operation is vital for great customer experience, and that’s what we focused on when developing Skygate’s highly automated technology,” commented Phil Hackney, Chief Operating Officer at The Very Group. “Throughout the pandemic, that technology has helped us to manage huge volumes of orders. It also enabled us to bring all of our clothing and footwear returns under one roof for the first time and means we’re well positioned for future growth.”

Despite a surge in orders during its first year as the pandemic fuelled demand for e-commerce, Skygate managed to deliver the performance required by Very. The automated picking, sortation and packaging technology from KNAPP means that orders can be ready for dispatch within 30 minutes, compared to around four hours at Very’s previous fulfilment centres. The fastest order to date, processed in July 2021, was ready for dispatch in just 17 minutes.

Operating 24/7, Skygate has processed over 40 million items since its launch and has significant potential for future expansion. The efficiency of processes at the facility, combined with the consolidation of three sites into one fulfilment and returns centre, will contribute up to £25m in efficiency savings per year for The Very Group. Skygate’s central location – close to the M1 motorway and adjacent to East Midlands Airport – combined with the on-site rail freight terminal will save Very an estimated one million road miles a year.

Designed for peaks

With Skygate responsible for the fulfilment of 95% of the Group’s customer orders, KNAPP worked closely with Very to ensure that the automation would be able to handle peak volumes with the required speed and accuracy. The logistics technology enables the pre-picking of orders on high-traffic days, which helped Very to cope with record-breaking Christmas and Black Friday trading in 2020. Sales for Very.co.uk increased by over 25% year-on-year in the seven weeks to Christmas 2020, with Skygate processing an impressive 3.9 million orders during this period, peaking at 265 orders per minute.

Key to both rapid order fulfilment and efficient returns processing at Skygate is KNAPP’s EcoPocket system. This pocket sorter technology uses a matrix sortation algorithm to arrange products in RFID-enabled pockets into the correct sequence to fulfil customer orders at the packing stations.

Items are placed in the pockets at a series of workstations, where totes of product arrive automatically from KNAPP’s OSR Shuttle Evo storage system. Taking an item from a tote, the operator scans it and drops it into a pocket with a single swipe action.

One of the largest shuttle systems in Europe, the automatic store features over 400 shuttles and provides almost 640,000 storage locations. Combined with 120,000 pockets in the EcoPocket system and 26,000 pallet locations in the manual store, Skygate houses an

One-touch returns handling

The automated handling solution at Skygate also enables one-touch processing of returns, with products available for resale within 30 minutes and customer refunds provided faster than ever before. Returns are prioritized, with two-thirds leaving the site within 24 hours and the overwhelming majority within three days.

A vast dynamic buffer of EcoPockets on the third mezzanine level of the warehouse makes returns processing a breeze and gives Skygate the capacity to handle 80,000 returned items per day.

Also featuring a dispatch sorter with 96 destination chutes, the automated logistics solution is controlled by KNAPP’s KiSoft suite of software, comprising Warehouse Management System (WMS), Warehouse Control System (WCS) and machine control systems for seamless integration.

“We are extremely proud to have developed this brand-new distribution centre from concept to reality in just three years,” commented Anton Tschurwald, Vice President Retail Solutions for KNAPP AG. “A strong spirit of partnership with the customer meant that Skygate was delivered within budget and on time, despite going live during the COVID-19 lockdown.”

To keep the complex project on schedule despite the lockdown restrictions, KNAPP worked with Very to develop – within just a week – the infrastructure and processes to continue start-up of the system by the British team with support from technicians working remotely from Austria. “The significant challenges were overcome through a potent combination of teamwork and technology,” said Tschurwald.

To ensure maximum system uptime, a 33-strong team of KNAPP Customer Service technicians is based permanently at Skygate, carrying out comprehensive preventive maintenance and dealing quickly with any issues that arise.

FM Logistic expands Bauhaus contract

Posted on by David Priestman

Third-party logistics company FM Logistic has renewed and expanded its e-commerce logistics contract with the German DIY retailer Bauhaus. The new contract has led to doubling the size of the Lovosice fulfilment centre, in the Czech Republic, from 30,000 to 60,000 sq m.

FM Logistic is managing Bauhaus’ online orders and distribution to consumers in Austria and Germany from Lovosice, a Czech town located near the German border. The cooperation started in 2018. Under the new contract, FM Logistic will handle a broader range of Bauhaus products. Bauhaus is indeed planning to bring the range of products stored in Lovosice from 30,000 to 100,000 SKU by 2030.

“In 2020, we handled 66% more orders than the year before. In 2021, we expect volume to increase by another 34%, which brings us to more than one million orders per year. To support this growth, we have been closely cooperating with Bauhaus to co-design and automate warehouse processes,” says Guilhem Vicaire, Business Solutions Director Central Europe at FM Logistic.

The contract covers further investments in automation. FM Logistic and Bauhaus have set up an on-demand packaging machine to produce the right size box for non-conveyable items. They have also invested in automated sorters and a goods-to-person picking system to improve order processing.

The additional warehousing space was delivered by P3 Logistic Parks. It was inaugurated in October 2021 by Johannes Wechsler, SVP E-Commerce & Digital at Bauhaus, and Jean-Christophe Machet, FM Logistic’s CEO.

“We decided to work with FM Logistic in 2018. Together we have succeeded in setting up an important link in our e-commerce logistics chain. We see FM Logistic as a strategic partner. That is why we have decided to extend our partnership by investing heavily in this fulfilment facility,” said Jérôme Biencourt, head of e-commerce logistics at Bauhaus.

FM Logistic expands Bauhaus contract

Posted on by David Priestman

Third-party logistics company FM Logistic has renewed and expanded its e-commerce logistics contract with the German DIY retailer Bauhaus. The new contract has led to doubling the size of the Lovosice fulfilment centre, in the Czech Republic, from 30,000 to 60,000 sq m.

FM Logistic is managing Bauhaus’ online orders and distribution to consumers in Austria and Germany from Lovosice, a Czech town located near the German border. The cooperation started in 2018. Under the new contract, FM Logistic will handle a broader range of Bauhaus products. Bauhaus is indeed planning to bring the range of products stored in Lovosice from 30,000 to 100,000 SKU by 2030.

“In 2020, we handled 66% more orders than the year before. In 2021, we expect volume to increase by another 34%, which brings us to more than one million orders per year. To support this growth, we have been closely cooperating with Bauhaus to co-design and automate warehouse processes,” says Guilhem Vicaire, Business Solutions Director Central Europe at FM Logistic.

The contract covers further investments in automation. FM Logistic and Bauhaus have set up an on-demand packaging machine to produce the right size box for non-conveyable items. They have also invested in automated sorters and a goods-to-person picking system to improve order processing.

The additional warehousing space was delivered by P3 Logistic Parks. It was inaugurated in October 2021 by Johannes Wechsler, SVP E-Commerce & Digital at Bauhaus, and Jean-Christophe Machet, FM Logistic’s CEO.

“We decided to work with FM Logistic in 2018. Together we have succeeded in setting up an important link in our e-commerce logistics chain. We see FM Logistic as a strategic partner. That is why we have decided to extend our partnership by investing heavily in this fulfilment facility,” said Jérôme Biencourt, head of e-commerce logistics at Bauhaus.

ZeKat launches logistics platform

Posted on by Keith McKinley

Pursuing its growth and development, ZeKat Group has launched a €4m investment project over two years to develop a multi-protocol mobile logistic platform. This gateway will integrate an open software architecture allowing remote management of embedded algorithms to ensure globalised logistics monitoring.

Since its creation in 2015, ZeKat Group has continuously grown to become a reference in IoT technologies and a leading mechatronics equipment manufacturer. The Group promotes French sovereignty in terms of design and production, particularly in the Defence, Industry and Agriculture sectors. For this last sector, the group has created a dedicated brand, IoF (for Internet of Fields), and launched a collaborative research project to develop an open and innovative technological ecosystem. With an investment of €1.2m, this project is dedicated to locally embedded artificial intelligence applications for the deployment of à la carte decision support tools in agriculture, as close to the data as possible (edge computing).

During the past few months, the Covid-19 crisis has brought to light a new paradigm: global demand is becoming unpredictable with changes in consumer behaviour, the activity of manufacturers is sometimes slowed down by health measures, and warehouses can be quickly congested or underused. Supply chain players therefore need, more than ever, visibility into pending orders, the state of production or stocks. In the meantime IoT paves the way for unprecedented levels of visibility, control and business intelligence which help to improve productivity and profitability.

Pursuing its commitment to create open and specialised ecosystems in specific sectors, ZeKat Group has decided to step up its presence in the logistics sector by developing a first dedicated brand, IoL (Internet of Logistics), which will combine all its knowledges and build specific offers. By associating the expertise of four of its subsidiaries, the group will develop a universal mobile IoT platform for logistics monitoring based on an intelligent gateway – a modular and open hardware and software platform allowing the integration of specific intelligence to support logistics decisions – and a device management platform.

This one will allow to manage the deployment of new services, remotely, by creating a digital twin and to deploy distributed intelligence models. The IoT platform must be able to combine several long-range (5G, LTE-M1 / NB-IoT, satellite IoT) and short-range (BLE, WiFi) communication networks and provide a guarantee of non-alteration based on the integration of blockchain elements.

This project, supported by the French Stimulus Plan, should enable France to position itself as a Global ecosystem in the development of secure IoT solutions to support major changes in the global supply chain. To do this, it wants to work with several major players in logistics and create a consortium of manufacturers. Its objectives will be to test, develop and promote the solution as soon as the pre-series are produced. This consortium will have to share a certain number of communication and data exchange requirements and validate them through the publication of a repository to promote a sovereign French solution that can be used by multiple actors.

These developments will be based on Ercogener’s 40 years of experience, a subsidiary of the ZeKat Group active in accurate geolocation (centimetre guidance), in the management of vehicle fleets (optimisation of fuel consumption) or in global logistics monitoring but also on the expertise of another subsidiary of the group, eRTOSgener, a specialist in embedded intelligence. The solution will be industrialised in France within AZKEDIA, which has an electronic solutions production site in Saumur.

Finally, this solution will be directly applied to the group’s new activity. Its subsidiary ZK-Systems produces containers that must travel from Saumur to their place of installation in Mali, without suffering major shocks under penalty of equipment breakage or theft of equipment during their journey. The containers are sent by truck to the port of Le Havre then by boat to Tanger then Dakar and finally by truck to Bamako.

ZeKat launches logistics platform

Posted on by David Priestman

Pursuing its growth and development, ZeKat Group has launched a €4m investment project over two years to develop a multi-protocol mobile logistic platform. This gateway will integrate an open software architecture allowing remote management of embedded algorithms to ensure globalised logistics monitoring.

Since its creation in 2015, ZeKat Group has continuously grown to become a reference in IoT technologies and a leading mechatronics equipment manufacturer. The Group promotes French sovereignty in terms of design and production, particularly in the Defence, Industry and Agriculture sectors. For this last sector, the group has created a dedicated brand, IoF (for Internet of Fields), and launched a collaborative research project to develop an open and innovative technological ecosystem. With an investment of €1.2m, this project is dedicated to locally embedded artificial intelligence applications for the deployment of à la carte decision support tools in agriculture, as close to the data as possible (edge computing).

During the past few months, the Covid-19 crisis has brought to light a new paradigm: global demand is becoming unpredictable with changes in consumer behaviour, the activity of manufacturers is sometimes slowed down by health measures, and warehouses can be quickly congested or underused. Supply chain players therefore need, more than ever, visibility into pending orders, the state of production or stocks. In the meantime IoT paves the way for unprecedented levels of visibility, control and business intelligence which help to improve productivity and profitability.

Pursuing its commitment to create open and specialised ecosystems in specific sectors, ZeKat Group has decided to step up its presence in the logistics sector by developing a first dedicated brand, IoL (Internet of Logistics), which will combine all its knowledges and build specific offers. By associating the expertise of four of its subsidiaries, the group will develop a universal mobile IoT platform for logistics monitoring based on an intelligent gateway – a modular and open hardware and software platform allowing the integration of specific intelligence to support logistics decisions – and a device management platform.

This one will allow to manage the deployment of new services, remotely, by creating a digital twin and to deploy distributed intelligence models. The IoT platform must be able to combine several long-range (5G, LTE-M1 / NB-IoT, satellite IoT) and short-range (BLE, WiFi) communication networks and provide a guarantee of non-alteration based on the integration of blockchain elements.

This project, supported by the French Stimulus Plan, should enable France to position itself as a Global ecosystem in the development of secure IoT solutions to support major changes in the global supply chain. To do this, it wants to work with several major players in logistics and create a consortium of manufacturers. Its objectives will be to test, develop and promote the solution as soon as the pre-series are produced. This consortium will have to share a certain number of communication and data exchange requirements and validate them through the publication of a repository to promote a sovereign French solution that can be used by multiple actors.

These developments will be based on Ercogener’s 40 years of experience, a subsidiary of the ZeKat Group active in accurate geolocation (centimetre guidance), in the management of vehicle fleets (optimisation of fuel consumption) or in global logistics monitoring but also on the expertise of another subsidiary of the group, eRTOSgener, a specialist in embedded intelligence. The solution will be industrialised in France within AZKEDIA, which has an electronic solutions production site in Saumur.

Finally, this solution will be directly applied to the group’s new activity. Its subsidiary ZK-Systems produces containers that must travel from Saumur to their place of installation in Mali, without suffering major shocks under penalty of equipment breakage or theft of equipment during their journey. The containers are sent by truck to the port of Le Havre then by boat to Tanger then Dakar and finally by truck to Bamako.

Peterhans benefits from micro fulfilment centre

Posted on by David Priestman

As part of a holistic realignment of its intralogistics, Peterhans Handwerkercenter AG, located at Würenlos near Zurich in the Swiss canton of Aargau, has remodelled and automated the logistics processes of its central warehouse and store for faster order processing and more storage capacity.

After comparing various AKL technologies and solution approaches, the family-owned company, founded in 1952, opted for an AutoStore solution from Element Logic.

“With around 500,000 articles, our multichannel strategy and our continuous growth, we wanted to invest in a system offers close to zero picking errors and maximum flexibility for future system expansions,” said Dieter Egloff, deputy managing director of Peterhans Handwerkercenter AG, explaining the main reasons for the decision. “Therefore, we examined various logistics facilities in practical operation and visited reference facilities with AutoStore solutions. When we weighed up all the factors, it quickly became clear: AutoStore technology was on our wish list. The simplicity of the technology, the flexibility of the storage concept and the output convinced us right from the start.”

Peterhans Handwerkercenter AG distributes building materials, tools, machines, fittings, fasteners and personal protective equipment directly to tradesmen and companies in the construction industry, making it one of the leading companies in this segment in Switzerland. Continuous growth, the servicing of different distribution channels promoted the decision to automate intralogistics.

“We are continuously strengthening our business through future-oriented investments in digitalisation and logistics,” Egloff said. “The automation solution allows us to handle volume increases with the same number of employees.”

The contract for system planning and implementation was awarded to system integrator Element Logic, the first official AutoStore integrator and the world’s most successful AutoStore distributor in 2020. With nearly 200 implemented AutoStore solutions, the company has extensive experience and a competitive edge in the planning, implementation and support of maximally efficient storage and picking systems for container-ready products. Based on this broad foundation, the system integrator is continuously developing further optimisation options in the field of AutoStore technology.

Integration of tailored system

For Peterhans, Element Logic installed an AutoStore system with a footprint of just 400 sq m for around 25,000 storage locations during ongoing operations in a two-stage project.

“The system includes 11,650 totes that are subdivided up to eight high,” said Egloff, illustrating the storage capacity. The 220mm-high bins used allow a load of up to 30kg with internal dimensions of 603 x 403mm.

“The main objectives of the automation project were to improve in-house logistic processes and maximise storage capacity in the existing building by increasing storage density,” said Joachim Kieninger, Director Strategic Business Development Element Logic Germany. “For an optimal layout of the facility, we analysed the very different sales channels and took them into account with regard to layout and processes.”

Peterhans supplies the shelves in the retail store from the central warehouse, orders via the online store, deliveries with its own vehicles to fitters and tradesmen, as well as output for direct pick-ups or orders in the store.”

For these goals, Peterhans and Element Logic already worked closely together in the planning phase. “The result is the perfect integration of an auto store system tailored exactly to our requirements into our existing building,” explained Egloff.

With the AutoStore automated storage and picking solution, the family business opted for an innovative storage concept in which the containers for small parts storage are stacked on top of each other in shafts and stored and retrieved by small robots. The system impresses with its efficiency and flexibility as well as minimal space requirements and comparatively low investment and operating costs.

The container stacks are stored in a standardised aluminium grid up to 5.4m high. The robots work on the surface of this grid. Depending on the container height, up to 16 or 24 bins are stacked on top of each other in a grid. The compact overall system with integrated workstations, the so-called ports, offers 60 to 70% better space utilisation than conventional miniload solutions.

The system layout can be adapted precisely to any structural conditions and is easily scalable with additional robots, ports or shafts to meet growing performance or capacity requirements. Consequently, AutoStore systems achieve the highest storage density among the available miniload solutions. The same applies to energy efficiency: with an average energy consumption of 100W per robot per hour, AutoStore systems have by far the lowest need for energy of all available miniload solutions.

In the system built for Peterhans, 20 bins are stacked on top of each other, adapted to the height of the hall. Ten robots move along the top of the grid. They lift the totes with the desired goods, transfer them to the workstations and stack the totes back into the system after picking.

Special feature: The system was realised in two construction stages due to the fact that it was implemented during ongoing operation. One of the advantages of the modular AutoStore concept, its high flexibility, came to the fore: first, one half of the grid could be conveniently erected, put into full operation and filled with goods. The empty shelving units were then dismantled and the AutoStore system was expanded to include the second half. This solidified the idea of connecting three of the six installed workstations directly to the sales floor.

“Customers are amazed and impressed to see an automated logistics system and transparent processes tied directly to the store,” Egloff said proudly. “This makes us very advanced – and allows us to offer customers something in additional, a unique shopping experience.”

The same applies to energy efficiency: with an average energy requirement of 100W per robot per hour, AutoStore systems have by far the lowest energy consumption of all available miniload solutions. With these attributes, AutoStore solutions form a proven basis for automated processes and fast order processing in modern micro-fulfilment centres, for example in online retailing.

97% fill rate

The workstation modules used in the AutoStore system are so-called carousel ports for higher warehouse throughputs and conveyor ports for lower throughputs. The carousel ports serve both as picking and repacking stations for loading the system totes.

Of the six ports at Peterhans, the three conveyor ports on the sales floor are used to retrieve goods for store customers. The three ports that are not visible in the store are used for retrieval of dispatching orders from the online store and for external deliveries to companies and fitters in the field, for example.

“In less than two minutes, a customer’s order is at the sales counter,” Egloff pointed out. “The system control of the AutoStore system knows which bin is in which place, calculates the routes and then distributes the driving orders to the robots via radio link.”

The robots work in a coordinated manner, quickly rearranging the totes, quickly releasing the required bins and filling them into the shafts for the integrated workstation modules. Thereby  the system automatically ensures that the bins are positioned according to ABC criteria: Less frequently requested containers slide successively further down, while fast-moving items remain continuously in quick access on the upper levels.

“Compact, high-density storage and fast, virtually error-free picking,” summarised Egloff. “With a system filling level of 97%, an average of 15,000 picks are made with the system per month – between 700 and 800 accesses per day.”

Immediately after installation, Element Logic’s AutoStore solution enabled the company to meet customer expectations for same-day delivery and shorter waiting times at in-store pickup counters. And the AutoStore system is also a great benefit for employees: “Our new, fully automated AutoStore system simplifies important loading processes and significantly supports our employees in their daily work. They no longer have to cover long distances or lift heavy goods. Overall, the picking processes are less labour-intensive for them than before.”

Element Logic ensures high system availability through its service team with preventive maintenance on site, as well as qualified telephone and online support.

According to Peterhans’ calculations, the investment in the AutoStore system will be paid off in five years. The flexibility of the storage system supported the two-stage project creation during ongoing operations as well as future growth.

“Without the AutoStore system, we would have had higher staffing requirements in logistics,” said Egloff. “With the AutoStore facility, we were able to meet the steady growth and even the rapid increase in online orders, because the retail store remained closed during the pandemic, without additional resources. An investment in the future from the very beginning. We can now count on a high-performance, automated small parts warehouse and our partner to meet our customers’ expectations for fast order fulfilment.

“And the system is still standing so well because we had such a good implementation partner in Element Logic. We are completely satisfied with the project handling, the cooperation and the results.”

The project details at a glance:

  • 400 sq m AutoStore plant footprint
  • 11,650 bins with around 25,000 storage locations
  • 10 robots
  • 6 ports
  • Simplified and ergonomic warehouse processes
  • Increased efficiency through automation
  • Important component of the digital transformation
  • Nearly zero defect picking
  • Same-day order processing and delivery
  • 80% Space savings offer future expansion potential
  • Highly reliable plant technology
  • Reduced burden on employees

CLICK HERE to watch a video of the project

Peterhans benefits from micro fulfilment centre

Posted on by David Priestman

As part of a holistic realignment of its intralogistics, Peterhans Handwerkercenter AG, located at Würenlos near Zurich in the Swiss canton of Aargau, has remodelled and automated the logistics processes of its central warehouse and store for faster order processing and more storage capacity.

After comparing various AKL technologies and solution approaches, the family-owned company, founded in 1952, opted for an AutoStore solution from Element Logic.

“With around 500,000 articles, our multichannel strategy and our continuous growth, we wanted to invest in a system offers close to zero picking errors and maximum flexibility for future system expansions,” said Dieter Egloff, deputy managing director of Peterhans Handwerkercenter AG, explaining the main reasons for the decision. “Therefore, we examined various logistics facilities in practical operation and visited reference facilities with AutoStore solutions. When we weighed up all the factors, it quickly became clear: AutoStore technology was on our wish list. The simplicity of the technology, the flexibility of the storage concept and the output convinced us right from the start.”

Peterhans Handwerkercenter AG distributes building materials, tools, machines, fittings, fasteners and personal protective equipment directly to tradesmen and companies in the construction industry, making it one of the leading companies in this segment in Switzerland. Continuous growth, the servicing of different distribution channels promoted the decision to automate intralogistics.

“We are continuously strengthening our business through future-oriented investments in digitalisation and logistics,” Egloff said. “The automation solution allows us to handle volume increases with the same number of employees.”

The contract for system planning and implementation was awarded to system integrator Element Logic, the first official AutoStore integrator and the world’s most successful AutoStore distributor in 2020. With nearly 200 implemented AutoStore solutions, the company has extensive experience and a competitive edge in the planning, implementation and support of maximally efficient storage and picking systems for container-ready products. Based on this broad foundation, the system integrator is continuously developing further optimisation options in the field of AutoStore technology.

Integration of tailored system

For Peterhans, Element Logic installed an AutoStore system with a footprint of just 400 sq m for around 25,000 storage locations during ongoing operations in a two-stage project.

“The system includes 11,650 totes that are subdivided up to eight high,” said Egloff, illustrating the storage capacity. The 220mm-high bins used allow a load of up to 30kg with internal dimensions of 603 x 403mm.

“The main objectives of the automation project were to improve in-house logistic processes and maximise storage capacity in the existing building by increasing storage density,” said Joachim Kieninger, Director Strategic Business Development Element Logic Germany. “For an optimal layout of the facility, we analysed the very different sales channels and took them into account with regard to layout and processes.”

Peterhans supplies the shelves in the retail store from the central warehouse, orders via the online store, deliveries with its own vehicles to fitters and tradesmen, as well as output for direct pick-ups or orders in the store.”

For these goals, Peterhans and Element Logic already worked closely together in the planning phase. “The result is the perfect integration of an auto store system tailored exactly to our requirements into our existing building,” explained Egloff.

With the AutoStore automated storage and picking solution, the family business opted for an innovative storage concept in which the containers for small parts storage are stacked on top of each other in shafts and stored and retrieved by small robots. The system impresses with its efficiency and flexibility as well as minimal space requirements and comparatively low investment and operating costs.

The container stacks are stored in a standardised aluminium grid up to 5.4m high. The robots work on the surface of this grid. Depending on the container height, up to 16 or 24 bins are stacked on top of each other in a grid. The compact overall system with integrated workstations, the so-called ports, offers 60 to 70% better space utilisation than conventional miniload solutions.

The system layout can be adapted precisely to any structural conditions and is easily scalable with additional robots, ports or shafts to meet growing performance or capacity requirements. Consequently, AutoStore systems achieve the highest storage density among the available miniload solutions. The same applies to energy efficiency: with an average energy consumption of 100W per robot per hour, AutoStore systems have by far the lowest need for energy of all available miniload solutions.

In the system built for Peterhans, 20 bins are stacked on top of each other, adapted to the height of the hall. Ten robots move along the top of the grid. They lift the totes with the desired goods, transfer them to the workstations and stack the totes back into the system after picking.

Special feature: The system was realised in two construction stages due to the fact that it was implemented during ongoing operation. One of the advantages of the modular AutoStore concept, its high flexibility, came to the fore: first, one half of the grid could be conveniently erected, put into full operation and filled with goods. The empty shelving units were then dismantled and the AutoStore system was expanded to include the second half. This solidified the idea of connecting three of the six installed workstations directly to the sales floor.

“Customers are amazed and impressed to see an automated logistics system and transparent processes tied directly to the store,” Egloff said proudly. “This makes us very advanced – and allows us to offer customers something in additional, a unique shopping experience.”

The same applies to energy efficiency: with an average energy requirement of 100W per robot per hour, AutoStore systems have by far the lowest energy consumption of all available miniload solutions. With these attributes, AutoStore solutions form a proven basis for automated processes and fast order processing in modern micro-fulfilment centres, for example in online retailing.

97% fill rate

The workstation modules used in the AutoStore system are so-called carousel ports for higher warehouse throughputs and conveyor ports for lower throughputs. The carousel ports serve both as picking and repacking stations for loading the system totes.

Of the six ports at Peterhans, the three conveyor ports on the sales floor are used to retrieve goods for store customers. The three ports that are not visible in the store are used for retrieval of dispatching orders from the online store and for external deliveries to companies and fitters in the field, for example.

“In less than two minutes, a customer’s order is at the sales counter,” Egloff pointed out. “The system control of the AutoStore system knows which bin is in which place, calculates the routes and then distributes the driving orders to the robots via radio link.”

The robots work in a coordinated manner, quickly rearranging the totes, quickly releasing the required bins and filling them into the shafts for the integrated workstation modules. Thereby  the system automatically ensures that the bins are positioned according to ABC criteria: Less frequently requested containers slide successively further down, while fast-moving items remain continuously in quick access on the upper levels.

“Compact, high-density storage and fast, virtually error-free picking,” summarised Egloff. “With a system filling level of 97%, an average of 15,000 picks are made with the system per month – between 700 and 800 accesses per day.”

Immediately after installation, Element Logic’s AutoStore solution enabled the company to meet customer expectations for same-day delivery and shorter waiting times at in-store pickup counters. And the AutoStore system is also a great benefit for employees: “Our new, fully automated AutoStore system simplifies important loading processes and significantly supports our employees in their daily work. They no longer have to cover long distances or lift heavy goods. Overall, the picking processes are less labour-intensive for them than before.”

Element Logic ensures high system availability through its service team with preventive maintenance on site, as well as qualified telephone and online support.

According to Peterhans’ calculations, the investment in the AutoStore system will be paid off in five years. The flexibility of the storage system supported the two-stage project creation during ongoing operations as well as future growth.

“Without the AutoStore system, we would have had higher staffing requirements in logistics,” said Egloff. “With the AutoStore facility, we were able to meet the steady growth and even the rapid increase in online orders, because the retail store remained closed during the pandemic, without additional resources. An investment in the future from the very beginning. We can now count on a high-performance, automated small parts warehouse and our partner to meet our customers’ expectations for fast order fulfilment.

“And the system is still standing so well because we had such a good implementation partner in Element Logic. We are completely satisfied with the project handling, the cooperation and the results.”

The project details at a glance:

  • 400 sq m AutoStore plant footprint
  • 11,650 bins with around 25,000 storage locations
  • 10 robots
  • 6 ports
  • Simplified and ergonomic warehouse processes
  • Increased efficiency through automation
  • Important component of the digital transformation
  • Nearly zero defect picking
  • Same-day order processing and delivery
  • 80% Space savings offer future expansion potential
  • Highly reliable plant technology
  • Reduced burden on employees

CLICK HERE to watch a video of the project

Pyroban acquires MEWP manufacturer Euro Access

Posted on by Keith McKinley

Explosion-proof safety company Pyroban has acquired specialist work platform manufacturer Euro Access Ltd in Cork, Ireland. The purchase has allowed the original founders to retire knowing their legacy will live on in a company they founded more than 20 years ago.

Euro Access, founded in 1996, manufactures ground support equipment specifically used for the maintenance of military aircraft. The specially designed access platforms enable maintenance engineers to reach the nosecone and other confined areas of the fighter jets.

“The area around each aircraft is formally classified as Zone 1, meaning a potentially explosive atmosphere is likely to occur during normal operations, so the access platform must be explosion-proof and meet ATEX 2G compliance,” says Steve Noakes, Managing Director of Pyroban. “To support safety, Pyroban was involved in the equipment’s original design process and certification in the 1990s with Euro Access’ founders Paul and Michael.”

Since then, Pyroban has continued to supply Euro Access with hundreds of explosion-proof kits which are fitted on the production line in Cork, Ireland. The strong relationship that developed led the founders to approach Pyroban as a suitable new owner in early 2021.

“Euro Access fits perfectly within our portfolio because it has great synergies with Pyroban’s innovative, safety-driven culture and bespoke engineering capabilities,” says Noakes. “It is also aligned with our existing support for many organisations in the military and aerospace sectors and opens up further opportunities to expand our offerings.  We are proud to be the new owners of Euro Access, starting a new and exciting chapter in the long-standing relationship.”

Euro Access was started by Paul McHugh and Michael Buckley, who had previously worked for leading Mobile Elevated Work Platform (MEWP) manufacturers. They saw an opportunity to develop the specialist equipment due to their technical knowledge, understanding of the military application, and ATEX experience. The company soon became an Approved supplier to BAE Systems Ltd. (formerly British Aerospace) and the wider military partnerships globally.

“Euro Access has been our passion for the last 25 years, but it is time for us to retire and let our legacy live on with a strong custodian that has the same values, principles and engineering excellence,” says McHugh.

Sussex (UK)-based Pyroban provides explosion protection conversions for materials handling equipment, including many other brands and types of MEWP. It also delivers and maintains explosion protected diesel engine packages and kits for well service applications. Pyroban is part of the Longacre Group, with strong financial backing to support ambitious acquisition plans over the next five years.

Pyroban acquires MEWP manufacturer Euro Access

Posted on by David Priestman

Explosion-proof safety company Pyroban has acquired specialist work platform manufacturer Euro Access Ltd in Cork, Ireland. The purchase has allowed the original founders to retire knowing their legacy will live on in a company they founded more than 20 years ago.

Euro Access, founded in 1996, manufactures ground support equipment specifically used for the maintenance of military aircraft. The specially designed access platforms enable maintenance engineers to reach the nosecone and other confined areas of the fighter jets.

“The area around each aircraft is formally classified as Zone 1, meaning a potentially explosive atmosphere is likely to occur during normal operations, so the access platform must be explosion-proof and meet ATEX 2G compliance,” says Steve Noakes, Managing Director of Pyroban. “To support safety, Pyroban was involved in the equipment’s original design process and certification in the 1990s with Euro Access’ founders Paul and Michael.”

Since then, Pyroban has continued to supply Euro Access with hundreds of explosion-proof kits which are fitted on the production line in Cork, Ireland. The strong relationship that developed led the founders to approach Pyroban as a suitable new owner in early 2021.

“Euro Access fits perfectly within our portfolio because it has great synergies with Pyroban’s innovative, safety-driven culture and bespoke engineering capabilities,” says Noakes. “It is also aligned with our existing support for many organisations in the military and aerospace sectors and opens up further opportunities to expand our offerings.  We are proud to be the new owners of Euro Access, starting a new and exciting chapter in the long-standing relationship.”

Euro Access was started by Paul McHugh and Michael Buckley, who had previously worked for leading Mobile Elevated Work Platform (MEWP) manufacturers. They saw an opportunity to develop the specialist equipment due to their technical knowledge, understanding of the military application, and ATEX experience. The company soon became an Approved supplier to BAE Systems Ltd. (formerly British Aerospace) and the wider military partnerships globally.

“Euro Access has been our passion for the last 25 years, but it is time for us to retire and let our legacy live on with a strong custodian that has the same values, principles and engineering excellence,” says McHugh.

Sussex (UK)-based Pyroban provides explosion protection conversions for materials handling equipment, including many other brands and types of MEWP. It also delivers and maintains explosion protected diesel engine packages and kits for well service applications. Pyroban is part of the Longacre Group, with strong financial backing to support ambitious acquisition plans over the next five years.

Subscribe

Get notified about New Episodes of our Podcast, New Magazine Issues and stay updated with our Weekly Newsletter.