Balingen/D. The challenge for every storage solution worldwide is the same: how to achieve the best overall outcome in terms of "time", "cost" and
"error reduction", without neglecting material and safety aspects. The German company Kempf GmbH opted for a combination of various storage strategies in the
construction of its new beverage logistics centre (GLZ) in Southern Germany.
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| The time factor
Some 8,000 of the 14,500 pallet spaces at the Balingen GLZ are operated on the basis of dynamic storage technology. There are good reasons for this and one in particular: the high
proportion of fast-moving consumer goods (FMCGs) in relation to total revenue. Although FMCGs only represent 160 of the 1,500 items distributed in total, they make up 80% of the
overall volume, with daily throughput of 1,500 pallets. Thus, it was only natural that systems integrator Rema Tec and EDEKA subsidiary A. Kempf Getränkegrosshandel GmbH once
again opted for Interroll dynamic storage technology. As Rema Tec Managing Director Peter Dippel put it: "Flow storage offers the greatest added value with fast return on
investment, as it greatly simplifies the process of monitoring expiry dates and inventory control. The uninterrupted provision of goods for order picking also contributes to
efficient workflow."
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| The error reduction factor
At the Balingen GLZ, storage of fast movers occurs on one of two overhead stock levels, with the first stock level designed as a pushback system with LIFO functionality (Last In,
First Out). This allows an increasing range of different items to be handled in an efficient and space-saving manner. After goods go into storage, repositioning occurs in bulk
lots on one of the order picking channels at ground level. Order picking is executed by pallet (65%) and roller containers (35%), with picking rates of up to 300 picks/person per
hour and error rates of well under 0.5% - thanks in no small part to dynamic storage technology.
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| The cost factor
Both the order picking levels and the second overhead stock level are managed by Interroll dynamic storage technology. The First In, First Out principle (FIFO) is strictly adhered
to for systematic reasons. It ensures both simple control and organisation of perishable goods as well as increased throughput rates, with the strict separation of replenishing
and order picking lanes generating the most significant benefits. It also means error reduction and time minimisation, all of which adds up to enormous cost-saving
potential.
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| The work safety factor
Safe pallet handling begins at the feeding point of any dynamic storage system. An entry guide centres the Euro pallets on the roller conveyor. Speed controllers optimise the
smooth running of gravity-driven pallets (200 - 1,000 kg) through channels up to 27 pallets deep. A special safety separator ensures a smooth starting motion on the unloading
side and thus makes it safer for the forklift drivers to unload goods. After unloading, the next pallet is brought forward by means of manual cable control, which ensures order
picking with zero-pressure accumulation.
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| Interroll at every turn
The associated empties sorting plant at the Balingen GLZ is configured for daily throughputs of up to 120,000 crates. The 230 incline roller conveyors for slow-moving consumer
goods with conveyor rollers supplied by Interroll are noticeable features of the 340 metre-long conveyor line. Other dynamic flow modules are used in the empty crate sorting zone
prior to consignment-specific provisioning of sorted batches. Empty pallets glide smoothly and safely on two Interroll wheel conveyor modules (known as "wheel flow for
crossway applications") to the forklift unloading side.
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