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Tag: KION

Everyone Can Automate Warehouse Trucks

Posted on by David Priestman

Oranges are not the only fruit, and in the world of warehouse vehicles brand differentiation is significant. Still Materials Handling, the ‘orange truck’, is automating its product line, as David Priestman reports from a press event in Antwerp.

In the charge towards warehouse automation materials handling OEMs want to avoid being typecast as just a forklift supplier or racking provider. Still’s new pitch is to be a systems integrator, while continuing to offer manually-driven warehouse vehicles. “We’re a one-stop-shop,” declares Managing Director Dr Florian Heydenreich (pictured). “70% of customers want to automate. We want them to think smart from the start and we’re providing customer-optimised products, robotics, hardware and software.”

The former factory of Egemin, the Belgian automated guided vehicle (AGV) pioneer, on the outskirts of Antwerp, is now Still’s automation competence centre, with 400 staff here. Since Egemin joined the KION group in 2015 (for a reputed €72m), expertise in AGVs has permeated to the rest of the group’s companies. The AGV market is forecast to grow by 18% per annum, driven by a need for process efficiency, cost control and the shortage of labour. Still, understandably, wants to rapidly gain market share. “Our aim is to advise and offer the best fit solutions, regardless of customer size and experience in automation,” Heydenreich adds, describing a holistic strategy.

“Automation is a hype, with five myths,” he explains:
1. Automation only works in new build facilities with high investment. This is not true as automation does not always replace manual operations, can be scaled-up and is therefore suitable for existing, ‘brownfield’ DCs
2. Automation solutions lack reliability. Automating cannot turn a bad operation into a good one without collaboration. 98% reliability is achievable
3. Immature technology. The biggest risk is the human factor. Companies must define standards, expectations and processes, for example regarding peak performance
4. Traditional materials handling providers are not innovative enough. We need to set standards for automation. Still has 600 employees working on simulation and project design
5. Automation is a purely contractual arrangement – the customer orders it and the integrator just implements. No – it is a joint approach, including change on the customer’s side, that needs time and consideration. Success requires close co-operation.

No forklift accidents without humans

Automation-as-a-service is what Still propose. An AGV is essentially a set of computers and sensors with forks and wheels. ‘Service readiness’ is key. Data is provided by every vehicle to the customer and to Still technicians for predictive maintenance. There no longer needs to be two different types of engineer – one for hardware and one for software as every technician can do all the work an AGV needs, using diagnostics and system updates. The machines have been ‘industrialised’, being built on the same production lines as manual trucks, making them cheaper and more highly available. For a three-shift, 24/7 operation, automation is the answer.

With two fleet management systems, ‘iGo Easy’ and ‘iGo Systems’, users can choose between standard or high-performance AGV fleets, with models such as the EXV 16 and AXV 12. iGo Easy does not require ERP or WMS and the user interface is any mobile device, with a lean project team. iGo Systems integrates AGVs into the customer’s WMS, with intelligent order allocation and storage location selection, to maximise throughput based on priority, weight of load etc. Data is stored on which AGV stores which load, where and when.

Reaching up, not out

The entire warehouse is mapped, creating a digital twin, for navigation, with precision to the nearest centimetre. The EXV has a lead time of just 8 weeks, from order to delivery. AGVs can be customised too. The company has many years of reach truck expertise and is putting that to good use with automated reach trucks, offering high-bay operations up to 7m and beyond. These AGVs can work in VNA warehouses with aisle widths as narrow as 2950mm.

Other automation solutions include AMRs, which learn from changes in the warehouse without re-programming, and the ‘iGo Cube’ for high-density storage, using AMRs. This is a pallet shuttle with WCS – a fully-automated ‘black box’. It takes six months to order and install a standard iGo Cube system, which can used in cold stores. All automation installations envisage a 12-year lifespan, with return-on-investment typically 3 years. Installation challenges often include the floor quality for AGVs to be able to drive at full speed and up to the maximum height, as well as when there are both pallets and totes being utilised.

Driverless installation

Third party logistics (3PL) provider Yusen Benelux’s Project Manager for Contract Logistics, Gitte Daelemans, talked me through the recent automation solution by Still for a 40,000 m2 greenfield hub, fully-automated warehouse. The DC is run exclusively for one large pharmaceutical company and features temperature-controlled zones (including vaccine storage for 11000 pallets), as well as quality control, packing and despatch and a secure area of 1440 pallets for hazardous products. Commenced in 2022, it went live last summer, undertaking 160 pallet transport per hour.

“This was a chance to automate,” says Daelemans. “The longer the 3PL contract the bigger the investment in automation. We defined the process implementation and what needed improving.” The DC is managed in a single integrated system, using Manhattan Associates’ WMS and provides smart integration of inbound and putaway processes. “It’s hard to find drivers with reach truck skills. But we still need staff for picking,” she points out.

The AGV vehicles operate in ambient conditions (35000 pallets) as well as in cool storage environments. The narrow aisle racking system has 10 automated VNA trucks – MX-X iGo, and 18 automated high lift pallet trucks – EXV iGo with sensor-based positioning. The EXV iGos deliver pallets to designated aisle drop-off points, where the automated VNA trucks pick them up and store them in the narrow aisle racks. This ensures high pallet throughput with minimal human intervention.

A full ‘day-in-the-life’ test prior to implementation helps to resolve any outstanding issues. “Volume testing is really important,” adds Daelemans. “Not just 1 or 2 machines but with inbound and outbound running to detect bottlenecks. This is difficult without the customer’s pallets being there before go-live.” She advises appointing a dedicated person to oversee the automated solution, along with implementing a contour scanner check for weight and measurement with an adjustable tolerance range that maximises acceptance, reducing rejection rates and the need for manual intervention. “We learned some lessons after go-live to be able to optimise things in the subsequent months and hit our KPIs,” Daelemans concludes, citing reject lanes and barcode readability.

Pragmatic approach

Still’s corporate culture is to be pragmatic. The company is not pursuing the highest-tech products for the sake of it, but rather the right technology and solution, sensibly. There has been a change in philosophy to ‘think automation’, instead of ‘building forklifts’. The company has the distinct advantage of having many customers already familiar with the brand, rather than being a new entrant to this space and Still is re-asserting its brand distinctiveness within KION.

I concluded my insightful visit by spending time with Frank Heptner, VP of Automation. An enthusiast, the former BMW executive embodies the upbeat Still attitude. “What is Still’s USP now?” I asked him. “Our local footprint, for installation and service is key, but we’re also a global partner; we’re everywhere, in every vertical market. We have a long history and our own DNA: Experience, stability and innovation,” he emphasises. And the competitors? “We have good coverage. There are lots of AMR suppliers, but few companies are automating larger AGVs,” he states.

What is the impact of automation on existing manual trucks? “There are 2 types of customer,” Heptner tells me. “Those that needed to automate years ago and those new to it. They’re all looking for automation. The speed of replacement of manual, driven trucks with ‘plug & play’ AGVs will accelerate. Perhaps a third of trucks will be automated in the foreseeable future.” Instead of training forklift drivers, managers will run a fleet of bots. For petrolheads like Heptner and myself that inevitability is sad, but true.

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KION opens Centre of Excellence for Automated Solutions

Posted on by David Priestman

The KION Group has opened the KION Automation Centre Antwerp in Belgium, a Centre of Excellence facility for automated solutions in EMEA. It is the first of its kind and now the primary hub for research and development, testing and customized production of automated solutions in EMEA. Employees from the KION brands will now work and collaborate on automation projects and individual customer requirements.

“Automation is the future for our industry, so I’m very excited about the new facility,” says Ching Pong Quek, member of the Executive Board and Chief Technology Officer of KION GROUP AG. “By bringing various capacities under one roof, we can now respond to market needs and deliver automation projects faster, more innovatively and cost-effectively. The teams design the right automation solutions for our customers and support our regional sales teams.” The new building allows new solutions to be tested and optimized on site and requirements to be addressed individually and quickly. “The Centre of Excellence will enable intensive collaboration across businesses with the aim of serving our customers even better”, says Quek.

Approximately 400 employees with diverse professional backgrounds and 40 nationalities are working at the KION Automation Centre Antwerp. The 11,800-square meter building is well equipped for collaborative work, with a flexible office concept encouraging creative thinking, learning, testing, and training. The building is located near the port of Antwerp in an industrial area that is set to grow and develop further in the coming years.

Cross-departmental collaboration an important success factor at new site

The employees who used to work in the two rented locations in Antwerp and Zwijndrecht have now moved into the new automation centre. It shortens distances and promotes cross-departmental team collaboration. One of the teams is KION subsidiary, automation and software specialist Dematic, which has vacated its previous offices and moved less than 100 meters away to the new building. The team provides centralized services on automated solutions for customers across Europe.

In addition to Dematic, other operating units of the KION Group are also based in the new building. One of them is KION Industrial Trucks and Services (ITS) EMEA, where a team handles customer projects from planning to delivery, including training sessions conducted in the office and test floors. They also focus on the testing and development of custom hardware and software solutions, as well as the production of customized solutions, particularly for industrial vehicles.

Robotic system development will play a major role in the new Centre of Excellence for Automation. The mission of the team is to deliver intelligent, driverless and interoperable robotic products, solutions and services that are easy to deploy, operate, maintain and support throughout their lifecycle in brownfield applications.

Building design focuses on solutions that support sustainability

The KION Automation Centre Antwerp features modern standards of sustainable design, such as advanced insulation, solar panels and a green roof. The goal is to achieve BREEAM sustainable building certification, which is based on a holistic approach to achieving environmental, social and governance (ESG), health and net-zero goals. From energy to ecology, a BREEAM assessment uses recognized performance measures against established benchmarks to evaluate a building’s specification, design, construction and use.

In addition, the KION Group is working closely with the European agency Encon to obtain a WELL Gold certificate from the US-based international WELL Building Institute. The WELL Building Standard is an evidence-based system for measuring, certifying and monitoring building characteristics that affect the health and well-being of occupants.

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Dematic Doubles-up to Reinforce Mission

Posted on by David Priestman

At the upcoming LogiMAT in Stuttgart, March 19th to 21st, Dematic highlights how every solution they design and install is focused on taking customers beyond merely meeting targets and propels their businesses to a far-reaching future able to tackle any obstacles on their individual journeys. Under the motto, ‘Solved: Your Ambition. Our Mission’, the leading provider of intelligent automation technology plans to demonstrate with their showcases how a complete focus on customers leads to solving challenges, helps them and their unique requirements.

For the first time, Dematic can be found hosting two stands at the largest logistics tradeshow in Europe: in Hall 1 H/61 and Hall 10 C/38 next to fellow KION Group brands STILL and Linde Material Handling.

Visitors in Hall 1 can expect an expanded interactive tradeshow experience over last year’s stand with several solutions to choose from. The focus is on automated processes and customer services for tomorrow’s warehouse. In fact, the Dematic technology showcases are found in Hall 1 while the stand in Hall 10 focuses on consulting services and demonstrations of KION Integrated Solutions – or KIS – from fellow brands Dematic, Still and Linde Material Handling.

“Our new claim can be seen as a kind of equation and these four simple words are all you need to know to solve it: every customer has ambitions to grow or change their business in ways that go beyond standard business goals. Some dream very large, while others perhaps smaller, but they all want to see their dreams become realities and by collaborating with a reliable and experienced partner such as Dematic,” explains Gunter Van Deun, head of Marketing, Communications and Business Development in EMEA at Dematic. “And we will have several projects on display at LogiMAT that clearly demonstrate this fact,” he continues.

Also on hand at LogiMAT will be Mike Larsson, the new president of Dematic, as well as Michael Jerogin, an executive vice president and the new Head of EMEA. Both are planning to use the time at the tradeshow meeting customers and visitors at the two stands.

The intralogistics experts are looking forward to unveiling a new bin-to-picker AMR solution. Here, autonomous mobile robots take over the automated removal and storage of containers from a rack storage system. Dematic also highlights its advanced software, which is seamlessly integrated into the AMR picking demonstration. Under the precise guidance of Dematic Software, the robots move effortlessly through the warehouse to transport the selected containers safely to the picking station, which will be manually performed in the showcase but can also be performed using a robot as automated piece picking. The AMRs also receive instructions from the operators. “The demonstration is a replica of an e-commerce order and shows the power of Dematic technology in managing assorted types of returns from replenishment processes,” says Van Deun.

A service showcase, which includes a comprehensive ergonomics check, is also integrated into the AMR picking demonstration. Future inspection processes will be shown using a live drone inspection and a thermology check, which ensures efficient monitoring of equipment and analysis of stock levels. “The showcase underlines Dematic’s pioneering role in integrating advanced technologies into its service offerings ahead of our competitors,” notes Rene Sickler, Managing Director, DACH at Dematic.

In addition, a case study involving the integration of two static pouch arms is scheduled to be visualized on a 4-metre-wide LED screen. An additional touch screen allows visitors to explore the pouch system’s technical details in an interactive way and thus gain a deeper insight into the performance and functionality of the technology.

The virtual hub also offers a unique opportunity to take a ‘flight’ through a warehouse, providing the visitors a fully immersive experience, showing many more of the solutions that Dematic can provide. This is made possible by L-shaped LED screens that represent the warehouse environment in reality. “The fly-through is intended to demonstrate how Dematic can support customers on the path to automation from start to finish,” explains Sickler.

“We have really packed a lot of technology into our display space this year and are certain we have something for everyone coming by our two stands,” beams Sickler.

New President of Dematic

Posted on by David Priestman

Dematic has announced that KION Group AG (KGX.DE) has appointed Michael Larsson (pictured) as President of Dematic Corp. and Member of the Executive Board of KION Group AG. Larsson succeeds Hasan Dandashly, who has retired from the company.

In his Board-assignment Larsson will also have responsibility for the KION Industrial Truck Segment (ITS) for the Americas while retaining responsibility for the Dematic Americas region.

“With his responsibility for the Dematic SCS business globally and ITS in the Americas, Michael Larsson will further drive our strong commitment to profitable growth. He will expand our integrated solutions strategy on lighthouse projects with top customers,” said Rob Smith, CEO of KION GROUP AG.

“It’s a very exciting time to lead Dematic, having the opportunity to work alongside an incredible team of industry experts to build upon our proud history and serving our customers. With the industry undergoing fundamental change, driving the need for increasing levels of automation, Dematic is in a great position to lead with innovative software and technology solutions. I would like to thank Hasan for his strong contributions to the company over the last five years building a strong foundation for future growth,” said Larsson.

A 35-year veteran of Industrial Automation and Robotics, Larsson has a proven track-record as a strategic business leader with a focus on customers and people. Most recently, he served as Executive Vice President of Dematic’s Americas Region responsible for accelerating growth and driving a market-leading presence in the US, Canada, Mexico and South America. Over the past three years, as leader of the Americas Region, he successfully led the company through complex challenges during the Covid-19 Pandemic as well as historical eCommerce surges of 2021 and 2022.

Prior to joining Dematic, Larsson served as Senior Vice President and Managing Director of ABB’s Automotive Business Unit. During his 30-plus-years at ABB, he also served in increasing levels of executive leadership, as CFO and Business Leader across four continents. He has a Bachelor of Business Administration from Stockholm University School of Economics in Sweden.

AMR Commissioning at Dutch Logistics Centre

Posted on by David Priestman

Dematic has recently completed the implementation of an autonomous mobile robot (AMR) solution for Radial Europe, a leading BTC e-commerce fulfilment expert and subsidiary of bpostgroup. The 299 newly installed AMRs move pallets and totes to transfer stations and picking stations at its logistics centre in Groningen, Netherlands. With the Dematic solution, Radial has enhanced its warehouse processes and anticipates significantly higher efficiency in order fulfilment. For Dematic, this represents its largest AMR order globally to date.

“Our customised end-to-end solution supports Radial’s goals of improving efficiency, increasing flexibility, and ensuring future scalability, which, in turn, will lead to an improved experiences for employees and customers,” explains Kevin Heath, the global director of robotics at Dematic, a global leader in the design, installation and support of intelligent automated solutions.

Radial uses the AMR system primarily to process e-commerce orders for apparel products. The system has three key application areas utilising three types of AMRs respectively:

• Pallet-to-picker AMRs transport pallets from the entrance to a large storage bay. From there, they are transported to transfer stations and picking station racks at the packing stations. The same process then takes place in reverse.
• Bin-to-picker AMRs handle pallet storage in an automated high-bay warehouse and transport them to the picking stations for the execution of split-case orders, including orders that consist of many individual products or article variants. To support this, the racking system has a capacity of around 65,000 locations for customer goods.
• Order-shelf-transport AMRs handle the transport of orders on a shelf with several levels, which are delivered to the packing stations.

Dries De Love, executive vice president at Radial Europe, says, “It’s a double win for Radial. The solution increases efficiency, resulting in improved services and lower costs for our customers. On top of that, we see ergonomic improvements and safety benefits for our employees, resulting in a stronger overall performance.”

The project at Radial’s Groningen facility marks a milestone for Dematic. Together with KION partner Quicktron, it has provided an innovative and full-scale AMR solution as well as its implementation. “This significant contract has helped establish best safety practices for this innovative technology as well as the strategy for customer service and spare parts provision within the EMEA region not to mention the template for best-in-class service for AMRs globally,” sums up Heath.

The project has provided Dematic with valuable insight into the application, design, and implementation of AMR systems. “It has allowed us to significantly expand our expertise in how to apply, design, and implement AMR order fulfilment systems, and we intend to continue to grow this line of business globally,” says Heath.

Linde Producing Hydrogen for in-house Material Flow

Posted on by David Priestman

It is a pilot project that is unparalleled in this industry in Germany and even throughout Europe: Using its own infrastructure, Linde Material Handling (MH) is now producing green hydrogen to power 21 fuel cell forklifts of its in-house fleet. On Thursday, May 11, the new hydrogen production facility and vehicles were officially put into operation at the Aschaffenburg site. The investment is being funded by the German Federal Ministry of Digital Affairs and Transport (BMDV), coordinated by NOW GmbH and implemented by Project Management Jülich (PtJ). The goal is to gain experience and build up expertise in order to be able to provide customers with comprehensive advice and support on the use of hydrogen in material flow processes.

“The topic of energy is emerging as one of the major challenges of this decade and beyond,” Stefan Prokosch, Senior Vice President Brand Management Linde Material Handling, said at the inauguration ceremony. “In our search for potential solutions, we identified hydrogen as an option in the energy mix of the future.” He pointed out that this applied especially to applications in intralogistics, because, in addition to potential climate neutrality, the rapid refueling of industrial trucks with hydrogen during intensive multi-shift operations posed a major advantage. “A three-minute refueling time corresponds to a comparable charging power of about 480 kW,” he explained. In addition, the energy carrier could act as an energy store with the increased use of renewable energy sources in the future, for example to temporarily store electricity generated by means of photovoltaics or wind power. “We want to have the entire range of energy supply options in our portfolio so as to be able to offer our customers the best possible solution for their specific needs. With this strategy, we will also be able to remain flexible and open to different developments. After all, no one knows exactly where this journey will actually end up,” explained the top brand manager.

Demonstrating courage, breaking new ground

Around 2.8 million euros have been invested in the planning and construction of the hydrogen infrastructure. The hydrogen production facility was built within a period of eleven months on a 280-square-meter area conveniently positioned within the manufacturing and assembly plant. Around 50 subcontractors were involved in building the hydrogen infrastructure under the direction of general contractor Covalion, a Framatome brand, and Linde Material Handling’s construction department.

“With the commissioning of the facility and forklifts, we ourselves are becoming hydrogen producers and users and will thus be able to further expand our technological expertise. This will eventually also benefit our customers because the experience we gain in planning, building and operating the plant and using the fuel cell forklifts will be passed on to them as part of future material flow projects,” stated Prokosch. At the same time, the decentralized on-site hydrogen infrastructure will serve as a showcase for other interested groups. “We will be demonstrating how the use of renewable energy sources can work in practice,” the brand manager added.

Kurt-Christoph von Knobelsdorff, CEO and spokesman of NOW GmbH: “Lighthouse projects like this one undertaken by Linde Material Handling are of great importance for the further ramp-up of hydrogen and fuel cell technology. They demonstrate what is already possible in the area of intralogistics and they make it clear that the transformation towards climate neutrality has gained momentum in the non-road sector as well. Companies that are leading the way in this regard and sharing their experience in networks such as the Clean Intralogistics Net are already benefiting today, ensuring their success far beyond tomorrow.”

Michael Kraus, project manager at Framatome (Covalion): “The project was a challenge, as well as an opportunity to demonstrate our skills and expertise. Planning the project and building the facility took a total of about three years – and we were able to accompany Linde Material Handling from our very first meeting to the approval process and the first fuelling of the industrial trucks. We worked closely with the project management team to meet the specific individual requirements of the project and find the best possible solution.”

State-of-the-art technology in inconspicuous containers

The components of the hydrogen infrastructure comprise several modules. The centrepiece is a PEM (polymer electrolyte membrane) electrolyzer, which is set to produce 50 kg of hydrogen per day. Here, purified and deionized drinking water is separated into oxygen and hydrogen with the help of green electricity. In another container, the hydrogen is gradually compressed to 450 bar and then fed into high-pressure storage tanks via piping and valves. A software-controlled valve system regulates the supply line to the dispenser, the gas pump. Here, employees can connect their vehicles in just a few simple steps. The refuelling process is completed within just a short time. The high-pressure storage tank is designed to store up to 120 kg of hydrogen at 450 bar so that even peak demand caused by increased refuelling processes at shift changes can be covered.

A total of 21 electric counterbalanced trucks with fuel cell hybrid systems, which comprise twelve Linde E50s with a load capacity of five tons and nine Linde E35s with 3.5 tons load capacity, replaced the previously used IC models. As part of the plant fleet, they are used for loading and unloading trucks and supplying the assembly lines with large and heavy components such as counterweights, pre-assembled frames or driver cabs, among other things. “The vehicles do not produce any emissions during operation,” Prokosch emphasizes. Hydrogen and oxygen in the ambient air react in the industrial trucks’ fuel cell system. The electrical energy generated charges a lithium-ion battery that powers the forklift; water and heat result as the only ‘by-products’.

The generation and use of hydrogen takes place directly where intralogistics operations are carried out. In addition to Linde forklifts, other technical solutions offered by the company are used as well. For example, the explosion-proof access control system of the Linde:connect fleet management solution ensures that only authorized and trained persons can use the hydrogen facility. Furthermore, the explosion-proof “Safety Guard” assistance solution at the dispenser and in the vehicles automatically reduces the driving speed in the vicinity of the filling station. Last, but not least, the ‘Linde Energy Manager’ solution enables the intelligent planning and control of energy demands throughout the site, thus avoiding power load peaks and allowing for cost optimization.

Hydrogen technology made by Linde MH

Linde MH is considered one of the pioneers in the use of hydrogen in intralogistics, having developed the first fully operational prototype forklift with fuel cell drive as early as 2000. Since 2010, fuel cell forklifts have been integrated into the company’s series production, and as of today, 80 percent of the series, including counterbalanced forklifts, tow tractors and pallet stackers, can be ordered with this energy option as a ‘customized solution’ with hydrogen drive. In numerous studies and projects, Linde MH and its partners from industry and science have demonstrated the conditions under which fuel cell forklifts are marketable and economical today. This is the case especially if a hydrogen infrastructure is already available on site or if highly pure hydrogen is produced as a waste product in the operational process. Fuel cell forklifts are also suitable for multi-shift operation entailing intensive use and a high number of annual operating hours indoors, or where there is limited space for charging or battery changing facilities, which are ultimately intended to be eliminated.

Along with the construction of Linde MH’s hydrogen infrastructure in Aschaffenburg, parent company KION GROUP AG is pressing ahead with the development and production of its own fuel cell systems. At the LogiMAT trade fair, Linde MH presented its first own 24-volt system for warehouse equipment, which was developed at the Aschaffenburg site. An approved funding decision has already been received for the development of a 48-volt fuel cell system, and the team is working on rapid implementation. “By bringing the development of fuel cell systems and lithium-ion batteries in-house, we will also have the opportunity in the future to design our own fully integrated fuel cell hybrid systems that are precisely tailored to the requirements of material handling equipment,” outlined Prokosch.

Enhanced Ergonomics for Higher Productivity

Posted on by David Priestman

Horizontal order picking still holds great potential in terms of optimization, especially with enhanced ergonomics. Corresponding measures are aimed at achieving the shortest possible walking distances between the vehicle and the rack location, as well as maximal ergonomics, in order to provide the best possible support and assistance for employees. The three new mast variants of the Linde N20 C SA semi-automated order picker enable operators to comfortably raise the truck’s forks to working height so that they needn’t bend down when handling the goods. This conserves the employees’ strength and energy and protects their physical health.

“Process and supply chains that are becoming more digitized, a growing number of product variants and, last but not least, demands for the highest possible pick rates mean that logistics managers in warehouses and distribution centres are increasingly looking for automated solutions,” says Manuel Seidel, Product Manager Automation. “While the actual picking process, i.e., retrieving the goods from the rack and placing them on the goods carrier, needs to be done manually, the Linde N20 C SA semi-automated order picker can at least assist the operator with moving in the rack aisle. This saves time and energy and increases productivity,” says Seidel, outlining the main advantages.

With the three new mast variants, the semi-automated order picker now offers operators even more benefits in the form of enhanced ergonomics. The compact Linde N20 C L SA is designed for order picking from the lowest rack level onto a pallet that can be loaded with 1200kg of weight. The forks on this model can be raised to an ergonomic height, allowing the operator to place the picked goods on the pallet while maintaining a posture that is easy on the back. Owing to its compact design, the order picker proves to be extremely manoeuvrable even when fully loaded. The Linde N20 C D SA, which offers a maximum load capacity of 1200kg on the main lift, can pick up two pallets separately and transport them one above the other in a space-saving manner. This mast variant is particularly suitable for longer transport distances. Heavy goods are transported on the initial lift, fragile goods on the main lift. The Linde N20 C LoL SA order picker enables the filling of two pallets in just one order picking cycle thanks to its long load arms and the additional liftable fork. The operator starts with one pallet at the desired height, while the second pallet is secured vertically to the back of the fork with a special safety device. As soon as the first pallet is filled, it is lowered onto the load arms and placed at the front of the fork. The second pallet is then transferred onto the forks and can also be loaded at a height that is easy on the back. In the process, the mast can be controlled to the right and left of the backrest.

More efficiency through semi-automated driving modes

The new mast variants expand the Linde N20 C SA’s range of applications. The main characteristic of the semi-automated order picker is the choice between two driving modes that are geared towards the two main customer applications: In the first, the worker moves in a U-shape in the rack area, initially picking only on one side and then switching to the other. The truck follows the operator through the aisle, avoiding minor obstacles and stopping automatically at the end of the aisle. If the operator stops to load up goods, the truck stops as well; if the employee moves forward, the truck continues on automatically. This saves operators a lot of walking, as they do not need to return to the driver’s platform each time to move the truck to the next rack position. The second travel mode is used when picking is taking place on both rack sides at the same time, resulting in a Z-shaped path. In this case, the operator sends the vehicle ahead using a remote control. At the end of the rack aisle, the operator gets onto the order picker and drives to the next aisle.

When asked for whom the semi-automatic order picker option pays off, Manuel Seidel says: “Depending on the application, an increase in efficiency of between six and 15 percent can be achieved. If you calculate an increase in productivity of around ten percent, the additional investment will have paid for itself in about a year in a two-shift operation with standard industry wage costs.” Another advantage is that the vehicles can be seamlessly integrated into the customer’s existing processes.

Safety at the highest level

To ensure a high level of safety, the semi-automated vehicles feature integrated high-performance safety scanners at the front that detect people, obstacles and other trucks and can thus prevent collisions. The vehicles also maintain a minimum distance of 50 centimetres from the rack to ensure a safe and comfortable working space for the operator.

New Distribution Centre has Latest Automation

Posted on by David Priestman

Ground was recently broken for a new distribution centre where Dematic is set to supply the latest warehouse automation technology to parent company KION Group at its site in Kahl am Main near Aschaffenburg, Germany.

When completed in roughly two years, brands within KION Group will use the facility for delivering spare parts across Europe. The goal is to ensure more efficient customer deliveries. Dematic is scheduled to install a highly dynamic Dematic Multishuttle® with 110,000 storage locations and 150 shuttles to handle automatic storage and retrieval. In addition, US-headquartered company is building a 6-aisle, scalable high-bay warehouse with a silo design and almost 24,000 pallet spaces. Fellow KION Group brand, Linde Material Handling, will supply several autonomous mobile robots (AMRs).

“This new, highly automated spare parts warehouse is a flagship project for both Dematic and the entire KION Group and a prime example of our combined strengths in terms of our own technologies within KION,” explains Andrea Campora, Senior Vice President at Dematic EMEA, adding, “Dematic and Linde plan to share the site when it is ready. It will result in a closer integration with employees from different areas benefiting from each other’s expertise.” While Dematic is a specialist in the Supply Chain Solutions (SCS) segment at KION, Linde has expertise in the Industrial Trucks & Services (ITS) segment.

In addition to more efficient processes, the new spare parts warehouse offers other benefits. “The logistics centre allows us to expand our production capacities, makes us less dependent on external supply chains, and lays the foundation for growing our business in German-speaking regions and beyond,” says Campora.

The new facility is also anticipated to create a near 100% spare parts availability. Dematic is expecting higher customer satisfaction through faster deliveries. Thanks to the environmentally friendly construction and a photovoltaic system, the CO2 savings also help to make the site as climate neutral as possible.

The new warehouse’s multishuttle is capable of handling different container type sizes to automatically store and retrieve goods. Items that are too large for totes and that cannot be stored in the multishuttle are packed onto pallets and stored in one of the six high-bay warehouse aisles. A special feature of the facility is that the multishuttle will be installed on a steel structure approximately five meters high. Picking workstations, packing stations, and other operational areas will be located under this massive platform. Smooth and automated material flow will be ensured by electric floor conveyors and modular conveyor systems from Dematic along with AMRs from Linde MH.

“The increased level of service allows the system to process orders that arrive by 4 pm on the same day,” Campora explains, adding, “These orders can then be in transit or already on-site the following day.”

The project once again underlines the close cooperation and comprehensive solution expertise under the umbrella of the KION Group. The ground-breaking ceremony took place at the end of February, and completion and joint move-in are projected for early 2025.

“Completion of this project is a milestone naturally internally for KION’s strategic goals, but the positive impact of this new facility will be felt by all of our customers and that is the way it should be – for the benefit of our customers,” sums up Campora.

Dematic designs, builds, and supports intelligent automated solutions empowering and sustaining the future of commerce for its customers in manufacturing, warehousing, and distribution. With research and development engineering centres, manufacturing facilities, and service centres located in more than 35 countries, the Dematic global network of over 11,000 employees has helped achieve approximately 8,000 worldwide customer installations for some of the world’s leading brands. Headquartered in Atlanta, Dematic is a member of KION Group, one of the world’s leading suppliers of industrial trucks and supply chain solutions.

New Electric Forklift Launched

Posted on by David Priestman

Baoli, the forklift manufacturer that is part of the KION Group, is launching a newly developed electric forklift series across Europe, the Middle East and Africa. The new trucks are cost-effective models designed for operation with lift capacities from 2.5 tons to 3.5 tons.

Electric forklifts are more environmental friendly compared to internal combustion solutions and therefore gain importance. To protect the environment and operator, Baoli is now launching a completely redesigned electric counterbalance truck family. The KBE 25-30-35 models have a load capacity of 2.5 t, 3.0 t and 3.5 t respectively. “This new generation of Baoli electric trucks aims at only one thing: Exceeding customer expectations! In terms of quality and reliability we are offering our customers a new reference in our market segment with the right level of performance at an affordable price. With the new KBE family we address all material handling standard applications,” says Francesco Pampuri, Director Brand Marketing & Management.

Robust, safe trucks for a wide range of applications

This new generation has been developed for suit almost all industries – from retail to manufacturing, from indoor to outdoor operations. The new machines draw their power from 80 V lead-acid batteries with a capacity of 360-450 Ah for the 2.5 t models and 500-600 Ah for the 3.0 t and 3.5 t models. Maintenance-free Li-Ion batteries will become available. “The solid workmanship of our machines ensures very long and smooth operation for our customers, whose safety is always our top priority,” Pampuri continues.

State-of-the-art production facility

The new KBE family is manufactured at the new production plant in Jinan (Shandong province), the fifth Chinese production site of the Frankfurt-based KION Group. The dimensions underline the growth aspirations KION has for the Baoli brand: the manufacturing area covers nearly 223,000 square meters – the equivalent of over 31 football fields. The new factory meets the highest manufacturing and quality standards and will allow Baoli to upgrade its range of forklifts for the entry-level segment to a completely new technological level.

Range of equipment

The KBE trucks come with a large number of technical features that make them reliable, safe and easy to operate. For example, the newly designed mast, which is up to 6,500 millimeters high, gives operators an excellent view of the load and its surroundings. It also features the “soft landing” safety function which reduces the lowering speed when the lift height is less than 100 millimeters. The new series features the latest-generation KION control unit, high quality electric motors and hydraulic components as well as the easy to read display. A driving program allows the operator to choose between economical, efficient or performance-oriented operation. Newly developed diagnostic tools can be operated via an app on any standard smartphone further increase the ease of operations.
BAOLI did not only focus on making the new electric trucks reliable and safe but also put an emphasis on driver comfort. For example, the spacious and comfortable driver’s seat offers operators a perfect all-round view through the standard overhead guard. Baoli is offering the truck with half or full cabins as well as retrofittable cabin kits if needed at a later time.

Excellent services

“Because we know what our customers really need, we make the decision very easy for them with the new KBE family because we offer simple, safe, yet very robust trucks without unnecessary extras. With easy-to-configurate and simple offer design and uncomplicated order processing, we also ensure a very high level of customer satisfaction,” Pampuri says. Baoli makes their forklifts available from stock out of their Italy-based distribution center in order to increase the flexibility of customers.

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