industry 4.0 Archives

[Podcast] Adapting to Industry 4.0: Intralogistics Automation

Posted on 15 April, 202525 July, 2025 by David Priestman

In our most recent episode of Logistics Business Conversations, host Peter Macleod engages in an in-depth discussion with David Hibbett, CEO of TGW Northern Europe, focusing on the transformative role of Logistics Automation in facilitating the transition to Industry 4.0. We discuss the challenges and transformations in the logistics sector, including labor shortages, the increasing demand for flexibility and efficiency, and the importance of cost-effectiveness.

David shares his childhood dream of becoming an astronaut and how he went from the sales department to being the CEO of TGW Northern Europe. The conversation delves into how automation technologies, specifically TGW’s Live Pick system, facilitate improvements in operational flexibility, scalability, and overall efficiency, allowing users to introduce additional bots to increase pick rate or add more racking to increase scale. David emphasises the growing importance of software and algorithms in logistics, as well as the critical considerations surrounding data security in an increasingly digitalized environment, and highlights the benefits of the shared data for users of their standardised system, allowing all operators to learn from each other.

From discussions around software and algorithms to data security, the episode provides a comprehensive overview of the challenges and opportunities in the evolving landscape of logistics. This episode is a much listen for all businesses that value flexibility and need to increase labour efficiency.

Click here to listen to this episode and more

Latest Automation Innovations at LogiMAT

Posted on 19 February, 202429 July, 2025 by David Priestman

Fives will present its complete ecosystem of smart and automated solutions at the LogiMAT tradeshow in Stuttgart, Germany (Hall 1 at Booth 1A61 & Hall 3 at Booth 3A30) from March 19 to 21st. This event will also be the opportunity to showcase its innovations designed to optimize the performance in material handling and automation.

Fives, through its Smart Automation Solutions Division, is an industry leading provider and integrator of cutting-edge, smart, scalable, and sustainable material handling solutions to increase warehouse automation. From retail and distribution to e-commerce, food, and 3PLs, as well as parcel and postal, Fives serves various business sectors, through an extensive range of technologies and software for conveying, sorting and picking the widest range of goods, worldwide.

Fives is dedicated to support its clients, providing them with comprehensive solution that increase speed, flexibility, capacity and scalability, to optimize the efficiency of their intralogistics
processes and deliver the right item, to the right place, at the right time. As a “customer-oriented company, Fives supports industrial companies throughout the entire life cycle of their facilities. From design to operations, Fives provides them with tailor-made and high-performance turnkey solutions, as well as aftermarket services ranging from spare parts, field service, maintenance programs, to retrofit solutions, anywhere in the world.

One innovation ahead

The rise of Industry 4.0 is deeply transforming the industry in various sectors. Automation innovation is key for addressing real-life challenges, such as digitally assisted remote services facilitating
AI-driven information collect and predictive maintenance. For over 60 years, Fives has been innovating, developing technologies that have become market standards. Anticipating customer needs, Fives invests in future technologies, expanding its solutions portfolio to collaboratively transform supply chain facilities with clients.

Take order picking to the next level

Speed, visibility, and reliability are essential for the success of logistics operations. To address the challenges associated with managing large order volumes while ensuring precise inventory management and efficient tracking of flows, Fives offers a warehouse automation solution based on the “Pallet-to-Robot” process, a new technological brick for automated pallet preparation.

A flexible, versatile, and scalable solution, AgileP2R ensures complete automation of order picking and adapts to the variability of logistics operations. It is designed for multi-product layer-pallets preparation and multi-product case-pallet preparation, and offers a choice of equipment, thus enabling customized adaptation possibilities.

For layer picking, Agile P2R features on one or more robots equipped with a layer gripper that can adapt to various pallet sizes. This gripper handles product-layers, up to 38 cm in height, using various technologies: suction, depression, clamping, security curtain.

For case picking, one or more robotic cells equipped with case grippers, which are adapted to all types of loads and take the fragility of the products into account, make up heterogeneous pallets. For both preparation modes, the use of AMRs complements robotics for maximum flexibility. 360° management software controls the entire process, and powerful algorithms automatically calculate and control the positioning of layers and cases to optimize pallets. Finally, a buffer area allows product pallets to be placed as close as possible.

Distance Sensor Sets Precision Standard

Posted on 20 December, 202329 July, 2025 by David Priestman

With the launch of its next-generation DT80 distance sensor, SICK claims to have revised the standard for measurement precision in materials handling, warehousing and logistics with a compact and robust device. Equipped with high-performance time-of-flight measurement technology, the SICK DT80 1D laser distance sensor achieves unparalleled accuracy of +/- 2 mm with a resolution of 0.1 mm at ranges up to 80 metres.

The SICK DT80 laser distance sensor uses a class 2 eye-safe laser to detect, measure and position on natural targets with no reflector. SICK has developed the DT80 with simple commissioning and versatile integration in mind, fitting even the tightest of spaces in both mobile and stationary machinery. With a robust metal housing, the DT80 delivers resilient performance despite challenging environmental conditions, such as mechanical vibrations, strong ambient light or extreme temperatures.

The outstanding precision and range of the SICK DT80 offer broad scope for both stationary and mobile machines, both indoors and outdoors. Typical applications in materials handling, warehousing and logistics include height detection of forklifts in automated transport vehicles, positioning of cranes and gantries.

‘Raising the Bar’ in Distance Sensing

“SICK’s development programme for the DT80 laser distance sensor has perfected our time-of-flight measurement technology and raised the bar in this class of mid- to long-range distance sensing,” explains Nick Hartley, SICK’s UK market product manager for distance measurement. “Achieving the best possible precision and repeatability is a constant challenge for many industrial measuring and positioning tasks.

“When engineers can trust the DT80’s repeatable performance, their mobile transport vehicles can operate without interruption and the need for adjustments. Accurate measurement is equally critical in diverse machine operations to ensure product and process quality. Ensuring minimal deviations reduces rejects, saves waste and reduces scrap.”

Simple Set-Up and Commissioning

The DT80 will accurately detect an object that has up to 90% remission at a distance of 80 metres. For objects with extremely dark surfaces and only 6% remission, it still achieves an impressive range of 14 metres. The SICK DT80 can be configured in a variety of combinations of distance and remission, helping to streamline inventories and make servicing more efficient. Setting up the DT80 is quick and easy using the icon-supported colour display. Four on-sensor LEDs also show the sensor’s current status and settings. Alternatively, the DT80 can be configured using HTML-based SOPAS engineering tool or using IO-Link.

Industry 4.0 IO-Link Connectivity

As well as enabling easy configuration, the DT80’s IO-Link connectivity enables data to be transferred and exchanged between sensors, actuators and OT control systems. Using an IO-Link-Master with OPC UA, data from the DT80 can be exported into on-premise and cloud-based analytics and remote diagnostics software, e.g. for condition monitoring.

At only 65 mm x 33 mm x 57 mm (HxWxD), the SICK DT80 is one of the most compact laser distance sensors on the market. Its cast zinc housing, durable PMMA sensor window, IP65 and IP67 protection and high shock and vibration resistance, ensure it operates reliably under the harshest industrial and environmental conditions. Since its housing and connectivity concept mirror SICK’s other DT distance sensors, users can easily upgrade to the SICK DT80 to take advantage of its greater precision and range.

Vertical Lifts, Ahead of the Curve

Posted on 20 July, 2023 by Keith McKinley

Traditionally a step ahead of the game with its vertical lift products, today, Kardex is a leader in warehouse automation. Peter MacLeod asked Kardex New Business Director for UK & Ireland Aaron Thornton to bring us up to date.

Aaron Thornton was persuaded to join Kardex after spending 20 years at a competitor. “When I was previously selling vertical lifts, it used to annoy me when customers would say they needed a ‘Kardex’. I’ve always had respect for the organisation, and a big part of the attraction of joining Kardex [two years ago] was their future commitment to automation. It is an organisation with a very stable background, excellent branding in the market and is correctly perceived to be the market leader. The company has a reputation for quality and stability.”

As Kardex continues its drive into the wider automation field, it has widened its focus from its previously core products – vertical lifts and carousels – and more on its newer technologies such as the Vertical Buffer Module. This, in conjunction with its picking software system (PPS), is driving the company to new heights and new segments.

“We’re a force to be reckoned with,” says Thornton. “We’re now able to attract a customer base that Kardex may not have communicated with previously, for example 3PLs and ecommerce businesses. We’re now looking at integration with conveyors, AMR solutions and robotics. Last year we also took on the AutoStore products to further widen our portfolio.”

My first touchpoint with Kardex would have been at an IMHX trade show in the early noughties. At the time its stand was dominated by a vertical lift that reached high into the rafters. “Back then, we were very product-led,” Thornton explains. “We don’t often take machines
to shows now. Yes, we have a leading product portfolio and that will continue to serve for many decades to come, but if you simply take a carousel or a vertical lift [to a show], that’s what you end up getting enquiries for. Kardex are now so much more than that.”

A solutions provider, Thornton says Kardex’s approach to Industry 4.0 is led by its software. “It takes our product range and lifts it to a different dimension. We also lead with pick technology and have a fantastic service offering called remote support. This enables us to dive
into the machines remotely in order to carry out assessments, for example servicing or cycles. We can see how the machines are performing live and plan preventative maintenance. That offers us a different dimension of sales support, which is a very exciting place to be.”

Kardex is particularly strong in an area Thornton calls ‘first-step automation’. “This is how we work with predominantly SMEs and larger businesses in order to lead them into their first foray into automation. “We are adapting as an organisation. We have robotics, conveyors, AMRs… That’s where the growth of the organisation lies, because that’s what customers demand. Automation was always something to
do with the big boys, but we can offer a level of automation at a relatively low cost, and that’s what makes us different.”

Vertical Lifts

Two major themes are emerging in 2023: labour shortage and high energy costs. Thornton believes Kardex is well equipped to address both of them. On the former, he says: “With a couple of machines and very good software we can manage pick patterns and throughputs that would previously require four or five people. We have discussions every week with our customers about the labour shortage, and we can help them overcome that.”

On the latter, he says: “We are always looking at the technology within our products to increase our green credentials. We have LEDs within
the machines to see what we can do to help lower customers’ energy bills. Companies that use a lot of automation look at their suppliers to
see how they can help them with that – we’re seeing kilowatt usage on motors becoming quite common in tenders.”

With a nod to Kardex’s heritage, this is a different company to the one I first encountered 20 or so years ago, and has its targets firmly set on the automated future of logistics.

Mosca Showcases TechCenter at LogiMAT

Posted on 22 February, 202329 July, 2025 by David Priestman

The main focus of Mosca’s appearance at this year’s LogiMAT from 25 to 27 April is on digitalisation and innovative service solutions. Stand 4D21 in Hall 4 is where the company will be using a tilt testing tool to offer insight into its newly opened TechCenter, in which customers can put their transport security systems to the test. Trade show visitors can also see live demonstrations of the new SoniXs TR-Connect, Mosca’s strapping machine designed for Industry 4.0.

“Mosca is much more than a machine manufacturer. We serve as professional partners for our customers’ sustainability and digitalisation projects,” explains Johannes Wieder, Sales Manager Logistics at Mosca. “And this is precisely what we want to demonstrate with our exhibit at LogiMAT.”

Mosca will not only be presenting its own machines at the trade show this year. Live demonstrations using a tilt testing tool will enable visitors to see quality checks on strapped products first-hand. Although the special machine is not part of the Mosca portfolio, it has been integrated into the company’s new TechCenter. This high-tech test lab in Waldbrunn enables customers to subject their cargo units and transport security systems to various stress tests and optimise them for sustainability as well as resource efficiency.

Wieder explains: “Many companies don’t notice that their transport security isn’t capable of withstanding high loads until the worst-case scenario occurs. This is why we developed the Mosca TechCenter as a service solution. Our customers can check a wide variety of load units and influencing factors to make adjustments to their packaging before the worst case occurs. Our display at LogiMAT gives customers initial insight into how the Mosca TechCenter operates.”

Strapped product pallets are placed in the tilt testing tool at the Mosca stand and tested for transport security. The machine tips the pallets to a predefined angle to test the stability of the bundled load when it is tilted. “Customers can run a full range of tests in our TechCenter: from acceleration and vibration to impact and crushing force testing,” Johannes Wieder explains. “The Mosca TechCenter is fully equipped to ensure customers can conduct tests that are most relevant to their transport processes.”

SoniXs TR-Connect introduced as Mosca’s new Industry 4.0 machine

Along with the introduction of the Mosca TechCenter, the market launch of the new SoniXs TR-Connect will also take place at LogiMAT. The basic principle of this high-tech machine is well established: Mosca is combining two previous models, the SoniXs TR-6 Base and TR-6 Pro, into the TR-Connect. Mosca innovation manager Andreas Ding explains the changes: “The new TR-Connect gives our customers more flexibility when it comes to further developing and networking their packaging lines. In the past, users who opted for a SoniXs TR-6 Base but later needed the functions of the Pro version had to replace the entire machine. The new TR-Connect can be easily adapted at any time and comes with all the functions that users need for Industry 4.0 applications.”

Key features include an integrated WebHMI that enables users to view all performance-related machine data, like availability and quality, at any time. The interface also makes commissioning and operating the SoniXs TR-Connect much easier because the machine can be remotely monitored at all times. An optional OPC/UA interface enables even greater flexibility. Thanks to compliance with the communication standard, the TR-Connect can be easily connected to a wide variety of interfaces to share information. Other options include the Mosca Digital Package, which makes it possible to use a tablet computer for easier machine adjustments.

Secure data exchange in the age of industry 4.0

Posted on 27 October, 202025 July, 2025 by David Priestman

Networked production processes and digital factories provide an important key to securing Germany’s competitiveness and innovative strength as a business centre. This is the subject of the lighthouse project IC4F – Industrial Communication for Factories – in which STILL has been significantly involved for almost three and a half years. The Hamburg-based intralogistics provider also hosted the final event, at which the results achieved with the project partners were presented on October 22nd.

For years, everyone has been talking about the future project Industry 4.0. However, essential tools for putting the new industry standard into practice are still lacking. The PAiCE support programme (Platforms, Additive Manufacturing, Imaging, Communication, Engineering) of the Federal Ministry of Economics and Technology is intended to remedy this situation. An associated lighthouse project is IC4F (Industrial Communications for Factories), in which the Hamburg intralogistics company STILL is playing a major role. “The 15 project partners from industry and research – including Robert Bosch GmbH, Siemens, Deutsche Telekom AG and Nokia – have spent the past three and a half years developing a technology kit for a trustworthy industrial communication and computing infrastructure,” explains Ansgar Bergmann, project manager at the Technology & Innovation department, who is responsible for STILL’s share of the project. This technology kit is based on an open architecture and allows modular extensions for new applications and communication technologies. Bergmann: “The results of our research will enable users to select suitable information and communication technologies according to industry 4.0 requirements and a specific migration approach”. These secure, robust and real-time communication solutions for the manufacturing industry will use key technologies from the areas of 5G, multi-access edge computing (MEC), cloud computing, virtualisation, industrial monitoring and analytics.

Ansgar Bergmann is particularly proud of the fact that STILL not only “simply took part” in this project, but was able to contribute their expertise to the fullest extent and decisively influence the development. “We have put our wealth of experience, which we have in the areas of industrial networking and Industry 4.0, to good use. In doing so, we benefited from the fact that we have already helped to develop several industry guidelines on behalf of the Federal Government and the VDMA in the past,” says the STILL expert. At the same time the Hamburg intralogistics company was also able to benefit from participating in the IC4F project. Bergmann: “First of all we proved to ourselves that we know how to successfully network processes in the warehouse and that our approaches work. In addition, we were able to gain many new insights, which we will now use in the cooperation with our customers to the benefit of both sides”.

Live demonstrations to underscore project success

On October 22, this work was provisionally completed. STILL invited project partners and internal stakeholders to the company headquarters on the Elbe. There, Nokia set up a mobile radio campus network, which was specially required for the project implementation and which will also serve as a pioneer for new communication technologies such as 5G. In several live demonstrations the equally important and groundbreaking results of the project work were then presented. One of the live demonstrations (“Use Case Truck-to-X Communication”), which was mainly developed by STILL, dealt for example with door control in a factory hall. In this use case both forklift trucks and other factory installations were integrated into a common communication environment. The indoor localisation system supplied the position data of the forklift trucks, which were then processed by various applications of the partners involved in the live demonstration. In this example, the door control was carried out purely from a virtual world. The door opened automatically as soon as a forklift truck approached it. This door control was implemented as a so-called administration shell. For this purpose, digital twins were generated from the forklift truck and the gate. In the submodels of the administration shell, all physical properties of the forklift and the gate, also called assets in this context, were then made permanently available. The virtual model, which also controlled the processes, was thus continuously able to compare these data and, for example, to open the door only when the dimensions of the forklift really fit through. In addition, the truck’s drive control is accessed and the driver is warned. Door damage as it occurs today would thus be a thing of the past.

Excellent customer benefit

During the event in Hamburg, several live demonstrations and a number of new or extended industrial use cases were shown, such as the “Bring your Own Network” approach developed by Siemens to facilitate the installation of Multi Tennant networks in companies, or a modern “Certificate Management via the Cloud” solution by Telekom, which increases both security and convenience in the field of industrial communication. “These proof-of-concept implementations serve to test the methodology and validate the use cases,” says Ansgar Bergmann. However, the STILL expert is firmly convinced that much of the knowledge and experience gained from the IC4F project will also be incorporated into industrial applications later on and will be of great benefit to STILL’s customers. Ansgar Bergmann is convinced that “with this experience as a basis we are the ideal partner when it comes to industrial 4.0 topics or warehouse networking.”

One innovation ahead

Take order picking to the next level

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