Why investing in existing intralogistics systems is worthwhile – and what matters most
Interview with Michael Hediger, EVP Sales & Services, Stöcklin Logistik AG in materialfluss SPEKTRUM 2025
In many companies, existing intralogistics systems are reaching the end of their technological or economic life. But instead of building new ones, targeted modernization not only extends their service life – it often results in a system that is more efficient, sustainable, and future-proof.
“Essentially, it's about securing a long-term return on investment,” explains Michael Hediger. “Many systems that we implemented 15 to 25 years ago are now reaching a point where they are technologically obsolete. Modernization can not only significantly increase performance, but also expand storage capacity and meet regulatory requirements.”
Conversion during ongoing operations: Planning is key
The biggest challenge? Conversion during ongoing operations. “Day-to-day business must not be disrupted, safety standards must be maintained, and everything must be planned down to the last detail,” emphasizes Hediger. A well-thought-out conversion plan, realistic time frames, and close coordination with the customer are essential.
Stöcklin relies on modern tools such as emulations: “We simulate the new system in a virtual environment – including interfaces. This allows us to eliminate sources of error in advance.” This reduces risks and minimizes downtime.
Sustainability as a modernization goal
Ecology is a growing issue. “Many customers are thinking ahead today: they don't just want a high-performance system, they also want to save resources and energy,” says Hediger. In many projects, the rack structure remains unchanged, with only the control technology and drive systems being replaced. Modern technologies such as intermediate circuit coupling and energy recovery help to significantly reduce energy consumption – by up to 45% in total.
Practical example from Switzerland: More space, less steel
A current project in Switzerland demonstrates the potential of intelligent modernization: Stöcklin is replacing two curve-following conveyors and a manual storage and retrieval machine in a 35-year-old system for an international pharmaceutical customer with seven double-deep MASTer 2024 systems. The result: 50% more storage space, three times the handling capacity – and thousands of tons of steel saved.
“The existing rack is being converted to double-deep use through targeted retrofitting. This not only saves resources, but also valuable space,” explains Hediger.
Conclusion: Better than new
Whether at Hermes Fulfillment, Miele, or Arvato, modernization is the more efficient path to the future for many companies. “Our customers benefit not only from higher performance, but also from more ergonomic workplaces, greater operational reliability, and lower operating costs,” says Hediger.
His tip for companies looking to modernize: “Focus on clean planning, an experienced team, and partnership-based collaboration. Then old quickly becomes high-tech again.”
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