WAREMA: Maximum storage density thanks to mobile racks

WAREMA stands for high-quality sun protection solutions

In the construction sector, the WAREMA brand is one of the leading providers of high-quality sun protection technology. Notwithstanding all economic fluctuations, the family company is on a stable growth trajectory. At their headquarters in Marktheidenfeld, Germany, however, WAREMA reached their capacity limits. Therefore, the management board decided in 2018 to build a new production and logistics center in nearby Wertheim, Germany. It opened in mid-2021. The logistics center now serves as a central distribution center for the European market.

How was the space in the warehouse optimally used?

WAREMA decided to collaborate with SSI SCHAEFER for the conception of the new logistics center. The intralogistics specialist scored points thanks to its many years of experience in constructing high-density storage solutions. 

At the heart of the system, there are seven heavy-duty mobile racks of type ESZ. “Mobile rack systems can be moved horizontally using a rail system and thus condensed into compact blocks. As a result, the customer only needs a single working aisle, which saves up to 45 percent in terms of space,” reveals Michael Wegner, Head of Sales Product & Equipment Central Europe at SSI SCHAEFER. “In comparison to fixed rack systems, the warehouse capacity is increased by more than 90 percent!”

Capacity increased thanks to narrow-aisle warehouse

“In our case, the values are even slightly higher,” adds Ulrich Liebler, Project Manager at WAREMA,  who co-developed the design of the shipping warehouse in Wertheim. “This is mainly due to the narrow aisle width we have chosen. At 1.5 meters, we are opting for a truly narrow aisle here. This way, we gain additional space for the racks, thereby further increasing storage capacity.”

In order to automate safely in a narrow aisle environment, high precision of travel movements and minimal tolerances in the travel path must be ensured. Liebler relied, to this end, not least on the robustness of the rail system and the carriages with which SSI SCHAEFER equips its mobile racks.

Cantilever racks offer the required flexibility

In order to reliably meet the different requirements in terms of weight, size, volume and sensitivity, each of the seven mobile rack systems is designed according to the specific requirements. The range of the goods to be stored spans from simple envelopes to highly sensitive packages with a length of up to seven meters and a weight of up to 200 kilograms.

The required flexibility is provided by cantilever racks that can accommodate load carriers up to six meters wide. This way, the shipping area has sufficient freedom to adjust the size of the storage locations to the delivery orders currently being processed. The entire shipping warehouse offers 20,000 meters of rack space for this purpose.

Semi-automated solution facilitates parallel operation of AGVs and manual forklifts

Four of the seven mobile racks are designed for the use of automated guided vehicle systems (AGVs). “Among other things, it was necessary to find a way to store and retrieve long goods pallets up to a rack height of 9 meters,” recalls Ulrich Liebler. “In a narrow aisle, you need a tailor-made approach. That is why we decided to collaborate with another automation specialist and then developed a viable system solution together with SSI SCHAEFER.”

At the moment, there are two automated guided vehicle systems in use. The complete solution also includes three forklifts that operate the non-automated mobile racks. If both AGVs are ever unable to operate, the forklifts can take over the processes in the automated warehouse area at any time.

By interlinking automated and non-automated handling, WAREMA can ensure maximum availability of the shipping warehouse. Currently, the throughput in the automated area is around 150 stock movements a day, and around 600 movements in the manual area.

Automatic aisle opening using SAP

The automation concept also includes the system opening the respective required aisle. To this end, WAREMA’s SAP solution was connected to the control system for the carriages. As soon as a new transport order is transmitted, the mobile rack system checks whether the required aisle is already available for use. If this is not the case, the aisle is opened.

Increased capacity improves delivery reliability

Direct access ensures that goods are delivered on time. “In the new warehouse, delivery reliability figures have improved significantly once again”, reports Ulrich Liebler: “With SSI SCHAEFER’s mobile rack systems, we have received a powerful solution which, in comparison to fixed rack systems, saves us more than 45 percent in terms of space. The combination of heavy-duty mobile racks and flexible cantilever arm technology enables us to handle the entire range of our product portfolio reliably in terms of processes. The high availability provided by the parallel operation of AGVs and manual forklifts is particularly valuable. We have thus gained the capacity and flexibility to fulfill our delivery promise economically and successfully continue on our growth trajectory.”

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