The modernization will make the dispatch of over 100 million books a year sustainable and efficient.
In this warehouse alone, 60,000 pallets are stored and on average over 2,500 pallets are stored and retrieved every day.
In accordance with Arvato's objectives, a future-oriented solution was sought that would impress through the use of energy-efficient technologies and the latest innovations in system and control technology.
The old pallet system technology was to be replaced and the new systems for the 14-aisle pallet high-bay warehouse installed in five stages (i.e. two or three aisles per stage) while the remaining aisles continued to operate, without any impact on the customer in terms of item availability and delivery speed.
Arvato opted for 14 high-performance MASTer42 storage and retrieval machines (SRMs) from Stöcklin. From March 2023 to January 2024, three devices were replaced every nine weeks during ongoing operations. First, the old rails and equipment were dismantled and removed. This was followed by the installation and assembly of the new guide rails and the new high-performance devices, including the connection of all interfaces. The work was carried out over four days using a 700-tonne lifting-in and lifting-out crane. The installation was carried out through an opening in the roof of the high-bay warehouse, with the incoming and outgoing goods halls within the crane's travel range. Due to the ongoing operation, consideration had to be given to loading and unloading trucks.
In addition, strong winds with squalls made it difficult to operate the crane during all operations.
Thanks to reliable project management and Stöcklin's high degree of in-house production at its Technology Center in Laufen (CH), the project start was only delayed to a limited extent despite material delivery delays at the beginning of the supply chain due to the outbreak of the war in Ukraine. All of Arvato's requirements were met: There were no interruptions to ongoing overall operations during the entire modernization phase. Desired customer adaptations were made possible during the construction phase.
Good reasons for Stöcklin:
On the one hand, the successful completion of the modernization at Miele in the vicinity of Arvato 2022 spoke for Stöcklin. Here, Stöcklin replaced the old systems with eight high-performance MASTer42 RBG systems within four years during ongoing operation.
In addition, the innovative sustainable energy management:
The newly developed sinusoidal energy recovery of the MASTer SRMs allows more than 12% of energy to be recovered and fed back into the grid. Together with the intelligent DC link coupling, a total of up to 30% energy can be saved.
"We are proud that we were able to complete the project without delays despite adverse conditions, including the outbreak of war in Ukraine and during ongoing operations. A decisive advantage was certainly the fact that almost the entire system and control technology was developed, designed and coordinated under one roof at the Technology Center in Laufen, allowing us to build on reliably good quality and lean processing."
Urs Hasler, Stöcklin project manager responsible for the modernization for VVA / Arvato
