The combination of two types of storage systems ensures optimal use of space and high speed for fresh food logistics, even with complex requirements.
Design and construction of a combined container stack channel and FSP shuttle system for efficient, process- and demand-oriented storage of fast- and slow-moving products.
A single-aisle, 7.2-meter-high container stacking channel storage system with a maximum of 25,326 storage locations, operated by a BOXer crane. Additionally, a single-aisle FSP shuttle storage system with 2,736 container storage locations across 12 levels (triple-deep), integrated with logOS software.
Extremely efficient use of space with high storage and retrieval speeds thanks to the combination of two storage types with three temperature zones in one hall.
Customized intralogistics solution enables intelligent and automated networking of industry-specific process steps (temperature-controlled storage and packing. Just-in-time picking of fresh products) in one hall.
Metzgerei Pfitscher is an internationally renowned manufacturer of high-quality sausage products and meat specialties. Its smoked products are produced in large batches and stored for several weeks, while the fresh meat and sliced products have a much shorter shelf life and are stored for only a few days. Containers of both slow- and fast-moving products are chaotically sent from production and packaging for storage.
The challenge was to sort and compactly store the slow-moving items, maintain the proper temperature for fresh products to ensure optimal processing, and deliver goods quickly and in small quantities to five order-picking workstations—all in a very confined space.
To meet these challenges, Pfitscher opted for a solution based on Stöcklin's analysis and planning, combining two different types of bearings into one cohesive solution.
Approximately three-quarters of the newly constructed hall was designated for a single-aisle container stacking channel storage system (GKL). Seven containers deep and three levels high, this system provides space for nearly 3,000 stacks of nine open E2 Euro standard containers (60 x 40 x 20 cm), each stack reaching a height of 1,720 mm and holding up to 25 kg of goods. A fully automated, 7.2-meter-high BOXer crane and a Stöcklin storage rover are used for storing and retrieving the maximum 25,326 stacked containers. The GKL is divided into three temperature zones, and products are automatically transported to the appropriate zone before processing, cutting, portioning, or packaging.
Next to the channel storage system is the single-aisle FSP shuttle warehouse for daily picking of fresh and ready-made products. This area can accommodate up to 2,736 containers, stored three-deep across 12 levels. Twelve Stöcklin FSP shuttles, each operating on a single level, move the containers, enabling a throughput of up to 1,440 boxes per hour.
The scope of the project also included the entire planning and construction of the transport systems in a food-processing-compatible execution, as well as the integration of an intelligent warehouse management and material flow control software. This software ensures first-in-first-out picking, links with incoming orders, and optimizes both capacity and energy usage.
The plant went into operation in October 2023, following nearly two years of planning and construction, despite the challanges caused by the COVID-19 pandemic. It represents a major milestone in the rebuilding of the plant at its original location after a devastating fire.
