Vertical Storage goes North

Modula, a leading provider of Vertical Storage Modules (VLMs) for any industry and application, has opened a new branch in Denmark marking the beginning of its expansion into the north. This strategic addition confirms Modula’s commitment to serving its customers more effectively and efficiently while further establishing its presence in the Nordic region.

With an impressive history in the field of automated storage since its first VLM was born in 1987, Modula has consistently delivered cutting-edge solutions to optimize warehouse and logistics operations, becoming a business partner for more than 20,000 customers around the world. The newest branch in Denmark, the ninth one in the world, marks a significant milestone in the company’s growth journey, enabling Modula to offer its state-of-the-art products and services to an even wider range of businesses in the region.

The Denmark branch, first of the planned northern additions, will allow Modula to work closely with existing and potential customers in the region, providing tailored solutions to meet their specific storage and retrieval needs. Therefore, Modula has hired a team of experienced professionals who are well-versed in the local market, ensuring that customers receive the highest level of service and support. To further enhancing customer satisfaction, this service will result in quicker response times for maintenance, technical support, and consultation.

In addition, customers in Denmark and the neighbouring countries will have access to Modula’s latest products, including vertical lift modules, horizontal carousels, customized software and picking solutions. All these products have been designed to improve warehouse efficiency and reduce operational costs in the supply chain. In accordance to Denmark and Sweden’s strong environmental values Modula remains committed to sustainability throughout the whole value chain. With Modula technologies, companies can minimize waste in all processes and create a better working environment for their employees.

Storage solutions for a wide range of local industries

“We are excited about the opening of our new branch in Northern Europe,” said Massimiliano Gigli, CEO and International Sales Director at Modula. “This expansion is a testament to our dedication to providing top-quality automated storage and retrieval solutions to our valued customers.” The company is looking forward to collaborating with businesses in Denmark to help them streamline their operations and achieve new levels of efficiency. This is also a mission close the heart of Jørgen Ladefoged, new CEO of Modula Nordics ApS: “After working for several years in logistics and industrial automation, I was seeking a new and exciting challenge that would combine innovation, growth, and a vision for the future. Modula’s rapidly expanding presence turned out to be the answer to what I was looking for. It’s a company that is continuously growing and is committed to investing more in the local market where it sees significant potential.”

Prior to its expansion plans Modula has taken a close look at the northern market to ensure that the newest locations are very well aligned with local trends and needs. Observations have shown that Sweden has seen notable developments in industries such as automotive manufacturing, information technology, electronic equipment production taking into consideration the geographical area and the ongoing growth trends. Denmark, on the other hand, is characterized by strengths in pharmaceutical production, technology, agriculture, food industry, renewable energies and sustainability. Meanwhile, Norway has a significant emphasis on oil and gas production and Finland on technology and manufacturing.

“I believe that Modula is the perfect product to introduce to the market due to its ability to adapt to any size, industry, and application. The work carried out in recent years with local dealers has allowed us to build brand awareness for our company, and we will continue to move in this direction to further establish our brand and make it known to all businesses, leveraging our international portfolio”, said Nicklas Lovqvist, Area Sales Manager Sweden. Modula’s expansion into Denmark and other Scandinavian countries aligns with the company’s mission to empower businesses worldwide with innovative, space-saving, and sustainable storage solutions. This new branch will complement Modula’s existing global network made by 4 headquarters (Italy, 2x USA, China), 9 branches (France, Germany, Spain, UK, Mexico, Singapore, Colombia, India, Nord Europa) and more than 100 Dealers around the world, consolidating the company’s position as a leader in the automated storage and retrieval industry. A new branch in Sweden will be added as early as the end of this year.

Podcast: The Future of High-Density, High-Performance Solutions

Episode 5 of our Podcast series, ‘Logistics Business Conversations’, is now available to listen to on Spotify, Apple Podcasts, Acast, Amazon Audible, YouTube, and other podcast distribution platforms – just search for ‘Logistics Business Conversations’.

“Don’t waste space in the warehouse, use the building’s volume,” is the advice from Editor Peter MacLeod’s guest in this episode – Damien Skinner, Country Manager of UK & Ireland for Hai Robotics EMEA.

Learn how automated picking and autonomous robots can collaborate to achieve fast storage and retrieval. How can storage density be maximised? Start small and add more robots after the proof of concept. Store up to 5 totes’ deep for ecommerce, apparel, general merchandise and irregular items. Productivity tips and ROI calculation.

Listen to any of our Podcast episodes here.

 

Automatic Small-parts Warehouse with Pallet Channel

ITH GmbH & Co. KG, a leading system supplier in the field of bolting technology from M16 up-wards, is using a new automatic small-parts warehouse. The company develops, produces and sells hydraulic, pneumatic and electric tools. ITH placed an order with the system integrator Klinkhammer Intralogistics with logistics planning and subsequently with the construction of an automated small parts warehouse and pallet channel warehouse as well as the retro-fit of the existing tray warehouse at the Meschede site. With this automation, a six-fold increase in the current logistical throughput, in terms of the number of order items, is possible in the small parts area. Existing and new warehouse systems will be equipped with the material flow control and the warehouse management software KlinkWARE 11.

As a medium-sized, owner-managed mechanical engineering company, the worldwide sales network includes twelve ITH subsidiaries and more than 40 worldwide representatives. In addition to bolting technology, the company also offers fastening elements, engineering services and a comprehensive service as a system supplier. The vertical range of manufacture of over 90 %, which is unique in the market, enables ITH to react flexibly and quickly to enquiries and to guarantee a high availability of components.

As the logistics had reached its limits in terms of performance, ITH commissioned the development of a future-oriented logistics concept that, in addition to expansions, would also take into account process optimisations of the existing warehouse technology. After a comprehensive logistics planning, which included all logistical areas from delivery to the supply of production to the dispatch of finished products, the decision was made to build a new automatic three-aisle container warehouse in order to significantly increase the picking performance. For an optimal logistical process, conveyor-connected combined workstations are planned between the tote warehouse and the existing tray warehouse, each of which has 7 replenishment tote positions and thus ensures a continuous flow of totes. The warehouse is optimally prepared for a significant increase in the parts assortment in the future, also due to the software-supported partitioning oft the load carrier. The container warehouse offers two different height classes.

In addition, a single-aisle pallet channel warehouse is to be built. The channel storage system is characterised by a particularly high storage density. Due to the multiple-deep storage, up to five pallets can be stored compactly one behind the other. The camera system on the stacker crane with an opening angle of approx. 180° is used for fast and targeted troubleshooting directly from the control room. In the course of this, the narrow-aisle warehouse will also be expanded and the existing tray warehouse will be modernised. In future, all warehouse systems will be equipped with the material flow computer and the warehouse management software KlinkWARE 11 and thus operated with a uniform software solution. The logistics centre is scheduled for completion in the first quarter of 2025.

The managing directors Frank and Jörg Hohmann as well as the project manager Jan Hohmann confirm the good cooperation: “We have experienced Klinkhammer as a reliable, innovative provider of logistics solutions and are looking forward to the completion of the logistics facility.”

Workwear Specialist Chooses Daifuku Miniload System

Portwest, a fast-growing online workwear company, has appointed global materials handling specialist Daifuku to design and install an automated storage system (AS/RS) at its distribution centre in Barnsley UK.

Due to go live by summer 2024, the warehouse automation system is expected to more than double handling capacity, thereby enabling Portwest to meet anticipated demand for its products, which include high viz jackets, PPE kit and safety gloves.

Based on proven technology adopted by brands such as Coca-Cola, Nike, Netto, UNIQLO and Honda, Daifuku’s planned AS/RS solution will facilitate the fulfilment of full carton orders and also replenish the linked goods-to-person system, which is also being introduced at the Barnsley location.

Currently in development, the AS/RS system comprises four high bay aisles serviced by four automated twin-fork mini-load cranes. High density racking will create more than 76,000 unique locations within the upgraded facility, significantly improving the efficiency of the 15,000 sqm warehouse.

Harry Hughes, CEO of Portwest explained why they selected Daifuku as their automation partner: “The introduction of this mini-load system is a major step forward for our UK operation, which is faced with a huge opportunity to increase sales throughput without moving to new warehouse premises. This will be achieved by embracing tried and tested automation technology, which will further improve service levels, enabling us to support our online customers in even more ways.”

Russell Hutchinson, UK sales manager at Daifuku, added: “This is a key project for us as it demonstrates our ongoing commitment to the e-commerce sector in the UK and its adoption of leading-edge automation to remain competitive.

“We are also pleased to have secured this project despite tough competition from other warehouse automation suppliers. We pride ourselves on the highest quality machinery and technology, which is matched by our open, honest and transparent approach to our customers.”

Portwest employs approximately 5,500 people across 130 countries. Headquartered in Ireland, the company was established in 1904 and remains a family-owned business which is currently managed by the third generation of the Hughes family. A global company, Portwest has already introduced Daifuku automation technology into one of its warehouse operations in Spain.

TGW’s New Stingray Shuttles

With covers made from locally sourced wood, the new generation of Stingray shuttle saves 25 tonnes of plastic per year. This is a step towards more sustainable, efficient, and reliable shuttles that transport totes, cartons, trays or hanging goods.

Thomas Gruber-Blanka, Director of Product Management at TGW, emphasises the impact of the new shuttles: “The latest Stingray generation unites the highest performance and reliability with energy-saving operation and sustainable materials. Users benefit from an extremely short commissioning time thanks to the Plug & Play concept. Complete data transparency also allows for condition monitoring and predictive maintenance. Both help to optimally schedule maintenance and increase availability.”

Built-in energy-saving function

The new generation of Stingray saves a substantial amount of energy during the hundreds of accelerations and decelerations per day. The Stingray stores braking energy in power capacitors and then make it available to all vehicles on the same level for acceleration. This saves energy when accelerating. What’s more, all shuttle and tote lifts are equipped with a standard recuperation function channeling unused energy back into the power grid.

Up to 90% decrease in manual intervention and 10% higher system performance

The Stingray also performs automatic health checks, detects twisted totes and resolves the issue without human intervention. This way, manual interventions are reduced by up to 90% and maintenance effort by up to 75%.

Yet, the main strength of the shuttles lies in their maximum performance range, whether in order picking or order consolidation, across normal, refrigerated and deep-freeze settings. In addition, storage-driven applications with lower performance requirements can also be covered efficiently by applying roaming shuttle principle. With a throughput exceeding 1,500 load carriers per hour, the latest generation of shuttles is the most powerful in the world. Its performance is 10% higher than its predecessor. The individual Stingray vehicles are 20% faster, with a top speed of 5 m/s.

With an impressive number of over 20,000 shuttles in use worldwide, the Stingray has long been the solution for a seamless transportation of totes and cartons as well as of trays weighing up to 50kg. The Stingray HG (Hanging Garment) is a special variant designed for transporting hanging goods, such as dresses, coats or suits, on hangers. The introduction of the Stingray with wooden covers sets a new standard for performance, reliability, and sustainability within the material handling sector.

TGW Logistics Group is one of the leading international suppliers of material handling solutions. For more than 50 years, the Austrian specialist has implemented automated systems for its international customers, including brands from A as in Adidas to Z as in Zalando. As systems integrator, TGW plans, produces and implements complex logistics centres, from mechatronic products and robots to control systems and software. TGW Logistics Group has subsidiaries in Europe, China and the US and more than 4,400 employees worldwide. In the 2021/2022 business year, the company generated a total turnover of 924 million euros.

Movu Robotics Opens HQ and Experience Centre

Movu Robotics, supplier for designing, developing, and implementing innovative and easier warehouse automation solutions, announces the opening of its new headquarters located in Lokeren, in the East Flanders province of Belgium.

Under a single roof, the facility houses engineering, R&D and production departments. It also features a state of the art of Experience Centre – one of the biggest in Europe where Movu Robotics’ latest technologies can be demonstrated live in operation to customers and partners. Logistics Business was given a tour on Monday.

As an independent business unit within the stow Group with different requirements to the stow Racking brand, Movu Robotics requires its own premises to produce its growing range of increasingly popular shuttles and robots. Movu’s new headquarters provides the room to support the continued and future significant growth in the robotics and automation business unit.

Lokeren is an ideal location: not too far from stow Group’s headquarters and conveniently situated between Ghent and Antwerp, which gives good access to a pool of skills required by the business, which is important given the number of people Movu will continue to hire going forward. The building itself combines a rare set of characteristics: it has large office area, covering approximately 5000 square metres, combined with a 10,000 square metre surface for logistics and manufacturing operations.

In addition, the building has an area of approximately 2500 square metres where it has a high ceiling, which provides the ideal space for the Experience Centre. which provides the ideal space for the Experience Centre. At 100m long, 25 metres wide and 20m high the Experience Centre is bigger than many actual warehouses, providing the ideal venue for Movu Robotics to present its product portfolio technologies: Movu atlas pallet shuttles, Movu escala bin shuttles, Movu ifollow AMRs and the new picking arm robot Movu eligo are all showcased in action, in a real life warehouse setting.

Visitors to the Experience Centre can see a 20m high Movu atlas pallet shuttle rack with lifts, has shuttles transporting pallets operating inside. There are Movu ifollow AMRs picking up pallets from
the racks and transporting them to different locations. AMRs can also be seen supporting picking from racking. There is a huge Movu escala bin shuttle warehouse containing 1000 bins with shuttles
operating inside. The Movu escala also demonstrates the Movu eligo picking robot application as well as conventional pick stations. A special attention is also devoted to the Movu software. Visitors can get deep insights into the self developed Movu Warehouse Execution System that is formed by three pillars: Movu ops for managing all operations, Movu tower for checking the available resources and selecting the most suitable shuttle or AMR and Movu pilot that ensures the execution of the order at the level of the individual shuttle or AMRs.

The Experience Centre has integrated everything possible into the demonstration rack, including a tunnel under the rack, a stairway around the vertical lift, a mezzanine with a picking area. There are also many software screens around the centre demonstrating the controlling software and how visibility of what is going on in a warehouse can be provided from a distance.

The expansive footprint of the Experience Centre provides room for three versions of every Movu Robotics system in its product portfolio o ne providing a permanent demonstration set up to be
available anytime ; a second set up for R&D purposes, which allows Movu to test new generations of products, or to test customer products for specific set ups; a third installation is for testing all products after assembly, before shipping to the end customer site.

In addition to customer visits there will be industry groups visits and workshops in the Experience Centre, which will act as a live and dynamic demonstration of what is possible now and, through
examining trends and market direction, how the needs of tomorrow can be answered.

Stefan Pieters, CEO of Movu Robotics, commented: “The new Movu Robotics headquarters in Lokeren is a centre of excellence, bringing together sales, R&D, manufacturing and one of Europe’s largest materials handling Experience Centres to provide a concentration of knowledge and expertise around robotics and automation. Creating a close connection between research, production and customer visits to the Experience Centre enhances Movu’s interaction with customers and provides the company with rapid market feedback to fuel our continued innovation and growth path.”

Automated, Accelerated Pharmaceutical Picking

Supply quality and first-class on-site services are crucial if retail pharmacies are to survive in the face of online competition. Therefore, the role of pharmaceutical wholesalers is also significant – they need to ensure not only high product availability, but also the fastest possible delivery. The company in this example has tailored its fulfilment concept precisely to these demands and implemented it with state-of-the-art technology from its long-term intralogistics partner SSI Schaefer. The latest highlight is the installed A-Frame with integrated product verification. This highly efficient, fully automated picking system provides up to 40,000 drug packages per hour during peak times on an order-by-order basis while meeting the pharmaceutical industry’s high standards.

In the course of a collaboration dating back over 20 years, this full-service pharmaceutical supplier has equipped all its distribution warehouses with high-performance technology from SSI Schaefer. This was implemented, in part, through retrofit, conversion, and expansion projects without impacting ongoing operations. The spectrum of installations ranges from manual to fully automated warehouse and picking solutions, including tailored logistics software from the WAMAS portfolio. SSI Schaefer’s Customer Service & Support includes on-site technical support as needed, alongside training and remote support.

Directly integrated, suitable for varying packaging

Through the implementation of the A-Frame, the partners have once again strengthened their shared commitment in the automation sector. The picking system was integrated directly into the existing structures and has proven to be ideal for picking small, fast-moving packing units since it was commissioned in the second half of 2022. Example contents include headache pills, nasal sprays, and adhesive bandages. A key feature of the A-Frame is the product channels, which allow flexible configuration and are the conduit for software-controlled, error-free output of various packaging sizes, whether cylindrical or rectangular, in just seconds. The items are ejected from the A-Frame onto the conveyor belt, where special sections are each assigned to one order, and then move directly through the filling point into the order bins. The entire process takes just 60 seconds.

High-performance automatic picking system for order fulfilment

The technical performance that can be achieved – up to 40,000 products per hour – is also based on the solution approach of decoupling the picking and refilling processes. Employees refill the A-Frames during lower-load periods. The system then performs fully automated picking, accelerating processing and accommodating the zero-defect strategy. This reduces the staff’s workload so they can be assigned other productive work in the distribution center, optimizing resource utilization. Thus the A-Frame ensures fast processing – even for complex jobs and during load peaks. If sustained growth continues, the system’s modular design will allow optional expansion and adaptation to specific new requirements.

Safety, speed, and efficiency as success factors

In addition, the A-Frame boasts a compact design that saves space, achieving especially high storage density on a small amount of floor space. The A-Frame can accommodate the majority of a product assortment, comprising well over 120,000 pharmaceutical products. Automation also makes an important contribution to meeting the drug safety requirements associated with zero-defect tolerance and full traceability. But speed is also crucial. Pharmacies often lack sufficient storage space to stock a complete assortment of products, so they rely on on-time delivery of the quantity of drugs ordered. The pharmaceutical wholesaler’s service closes this gap, enables a successful customer experience in the local environment, and strengthens the pharmacies’ competitive position, while permanently reducing its own process costs.

Installation of Systems at Weiss Technik

Dematic has completed the installation at two Weiss Technik sites of stand-alone AutoStore™ systems and the commissioning phases have also recently been completed. The system at the German headquarters of the market leader for environmental simulation equipment in Lindenstruth, Hesse, completed commissioning in Q1 of this year. The energy-efficient systems are controlled and operated with SAP WM Go warehouse management software, which Dematic has integrated with existing ERP systems.

Weiss Technik is a member of the Schunk Group, which is a leading supplier of products made from high-tech materials, such as carbon, technical ceramics, and sintered metal as well as machines and systems, including environmental simulation and air conditioning to ultrasonic welding and optical machines.

Niko Hoffmann, project engineer at Weiss Technik, says a critical factor in the decision to work with Dematic was that the solution is scalable and can be expanded without major restrictions, even during operation. Additional bin locations can be easily implemented via grid extensions and more robots can also be integrated quickly.

“Our decision to go with Dematic was based on a long-term perspective. With its global network of engineering professionals and many years of experience in warehouse solutions, it was important to select a reliable partner with the highest quality standards and expertise,” explains Hoffmann.

At the Lindenstruth site, nine robots transport as well as store and retrieve approximately 13,400 bins. The bins can also be divided into further compartments to hold additional items. The robots travel on the surface of the structure, accessing bins with requested goods as needed. They then transport the bins to the picking workstations. The compact unit-load picking AutoStore™ systems have a high storage density and automate both production supply and spare parts dispatch at Weiss Technik.

At the other location in Balingen in Baden-Württemberg, Dematic has installed an AutoStore™ system with approximately 6,300 bins and nine robots as well. A roller conveyor connects the picking workstations with the respective production areas to eliminate unnecessary walking and secondary activities by employees. In addition, there is no need to refill goods, which results in additional time savings. “As a result, the systems should lead to significantly higher picking performance with a lower error rate,” says Hoffman. Multiple stabilisation towers ensure smooth operation in one of the highest seismic zones in Germany. The towers have been installed together with the AutoStore™ system with the grid fixed to them. Dematic has taken on the role of general contractor.

Energy efficiency was also a factor. Notes Winnie Ahrens, sales director DACH (Germany, Austria and Switzerland) “Because of its extremely compact storage and its low energy consumption, the AutoStore™ concept is environmentally friendly and thus fits perfectly with Weiss Technik’s sustainability approach.”

Energy is recovered when the robots brake and when the bins are lowered. Since no lighting is required and the AutoStore™ space requirements are low with less building space to maintain, Weiss Technik benefits from further energy savings.

“Despite the severely impacted global supply chains that every business relies on, we managed to complete the dual order for Weiss Technik on time and on budget, which is outstanding given today’s challenges,” says Ahrens.

Collaboration with Dematic is anticipated to be strengthened, says Hoffman. A framework agreement has already been signed with the Schunk Group, the holding company for Weiss Technik, for additional solutions featuring AutoStore™ systems. “We look forward to future cooperation with the Schunk Group and Weiss Technik,” says Ahrens.”

Podcast: Automation: The Future of Your Warehouse

The fourth episode of our Podcast series, ‘Logistics Business Conversations’, is now available to listen to on Spotify, Apple Podcasts, Acast, Google Podcasts, Amazon Audible, YouTube, and all other podcast distribution platforms – just search for ‘Logistics Business Conversations’.

Warehouse Automation is in vogue at the moment due to labour shortages and costs, but the issues are more complex than that. Learn from industry leader Jungheinrich, who provide the full spectrum of materials handling products. What is the future of robotics and forklift trucks? Peter MacLeod talks to Jungheinrich UK MD Paul Lynam and Director of Projects Spencer Goss about customer needs and future trends.

Listen anytime on your preferred platform or by clicking here. Watch our recent Webinars or listen to any of our Podcasts here.

Jungheinrich UK is a leading material handling solutions provider. It is a subsidiary of Hamburg based Jungheinrich AG which employs 19,000 colleagues around the world. Jungheinrich provides a holistic range of products and services in terms of equipment & solutions, warehousing and material flow engineering. Jungheinrich is leading the way with the latest technology including Lithium-Ion batteries and warehouse automation.

The company’s Logistics Systems division offers warehouse concept design and material flow analysis, project management, installation of pallet racking and shelving right up to semi and fully automated warehouse solutions such as Automated Storage & Retrieval Systems as well as Autonomous Mobile Robots and Automated Guided Vehicles.

Jungheinrich UK is headquartered in Milton Keynes and has a large warehouse, workshop and regional head office in Warrington. Jungheinrich currently employs over 750 staff in Great Britain and Northern Ireland, of which almost 500 are working in the Customer support & Aftersales sector.

Jungheinrich celebrates its 60 year anniversary in the UK in 2023. This landmark helps highlight a wealth of experience at the forefront of materials handling solutions and, more than ever, instils the confidence that the company can find the perfect solution for any application.

Fastpick Live in State-of-the-art DC

Vanderlande has delivered its highly-automated FASTPICK solution to VF Corporation (VF), one of the world’s largest apparel, footwear and accessories companies. The goods-to-person (GtP) system, which incorporates innovative ADAPTO shuttle technology, has been installed in VF’s new state-of-the-art distribution centre (DC) in Ontario, California, and went operational this month.

VF selected Vanderlande to supply FASTPICK for the new DC because of the solution’s flexible and scalable design. It’s capable of delivering high-performance sequencing on a relatively small footprint, making it both an efficient and sustainable solution. The collaboration builds on a solid foundation, as the two companies have already successfully executed three warehousing projects in Europe.

The new facility is the largest and most efficient in VF’s global network of 46 DCs. With the capacity to ship 485,000 units per day, the DC provides more efficient services for the company’s own retail stores and wholesale customers, while fulfilling next day e-commerce orders for consumers in California, Nevada, Arizona and southern Utah. Initially the centre will service the Vans® and The North Face® brands, but will be capable of adding more brands from the VF portfolio in the future.

Vanderlande’s end-to-end solution covers all operations from receiving and storage, through to picking, packing and shipping. ADAPTO, Vanderlande’s shuttle-based automated storage and retrieval system (AS/RS), is central to the operation. The AS/RS supplies orders to the 28 ergonomically designed, height-adjustable GtP workstations, which are capable of handling 10,500 order lines per hour.

“We are proud to introduce VF’s largest and most efficient distribution centre to date,” says Cameron Bailey, VF’s Executive Vice President Global Supply Chain. “Servicing our consumers and customers is our number one focus. This facility allows us to get our products to our consumers faster using technologically advanced equipment, which results in reduced lead times and increased efficiency in meeting consumer demand.”

“We’re delighted to partner with VF to implement our market-leading, future-proof automated warehouse solutions,” says Francisco Moreno Velo, Vanderlande’s President of Warehouse Solutions North America. “FASTPICK’s flexibility will help the company meet customer demand across all sectors – wholesale, retail and e-commerce – while providing an ergonomic working environment for its operators.”

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