The Handtmann Group decided to expand its existing logistics centre with a significant new building. After an intensive selection process, Dematic was chosen for the conception and implementation of this major project. 

Quality and precision have been key ingredients in the Handtmann Group’s recipe for success for many years because customers expect flawless systems from the Biberach-based company. Handtmann has expanded over the years with broad diversification and is now a global player with offices and production facilities all over the world. What has not changed, however, are those extremely high customer expectations. 

That is why when it came to upgrading its logistics centre for increased capacities at the headquarters in Bieberach, Handtmann carefully considered it options for the right solution.

Founded almost 150 years ago as a brass foundry, the Handtmann Group has developed over time into a globally active system and plant manufacturer. Today, with almost 4,000 employees at 30 locations worldwide, the company has annual revenues of 820 million Euros. In the business area of filling and portioning systems, Handtmann develops and produces future-oriented application solutions for food processing. It is a world leader in this industry, and its customers include craft businesses and start-ups as well as medium-sized companies and industrial groups.

The large product diversity of Handtmann creates special demands on the warehouse technology. In addition, the volumes and throughput in its warehouse in Biberach an der Riß have grown significantly in recent years. Consequently, it became necessary to replace its existing pallet warehouse and automated small parts warehouse as Georg Briegel, Head of Production at Handtmann Maschinenfabrik GmbH, reports, “On the one hand, our goal was to expand our storage capacity. On the other hand, it was necessary to optimise processes.”

In search of a modern solution, Handtmann looked to automation technology provider, Dematic. Together, the two companies redesigned and expanded the logistics centre with a new 6,000 square metres addition with direct connection to the existing production facility. Dematic provided a holistic layout consisting of a Dematic multishuttle system and a high-bay AS/RS with three stacker cranes and various conveyor technology, all controlled by Dematic software. The old facility was dismantled after the completion of the new Dematic system. 

One of the biggest challenges was the need to implement the solutions while production continued to operate. After a planning and construction period of 30 months, the new warehouse was fully operational. At the beginning, Dematic first replaced the existing pallet warehouse with a high-bay warehouse and then supplemented it with a large Multishuttle system, which was installed on a newly built reinforced concrete platform. In addition, the pallet and container conveyor technology as well as the workstations for incoming goods, order picking, quality control, spare parts shipping, and production supply were renovated. “As a result, we are now able to react quickly to changes and improve our internal material flow,” says Briegel. Compared to the previous system, for example, the supply of spare parts at Handtmann is now many times faster and allows up to 3,800 picks per day.

The high-bay warehouse now offers space for 7,200 pallets, which can be stored on 25 levels in three aisles. Thanks to the automated pallet storage, up to 129 combined storage and retrievals – FEM double cycles – are possible. In addition, the new two-aisle multishuttle warehouse holds around 64,000 containers, each with a weight of up to 30 kilograms, which are distributed over 41 storage levels. There are 550 double cycles possible. After receipt of the goods, they are first distributed to containers, which are then automatically transported to the small parts warehouse and stored. A weight check ensures that the permissible maximum weight of 30 kilograms per container is not exceeded.

The new logistics centre has four goods-to-person picking stations with pick-to-light systems. In addition, there are five workplaces for incoming goods, seven workstations for outgoing goods, eight workplaces for quality inspection, one workplace for returns, and four workplaces for internal storage and removal. Dematic conveyor connects the warehouses, automatically transporting the goods. And because of its modular design, the conveyor system can be adjusted and expanded to accommodate future requirements. 

The control and operation of the new systems are carried out by Dematic software, which allows the existing storage resources to be used in the best possible way. The software optimises operations using advanced analysis methods and algorithms. Warehouse data are recorded in real time and displayed on computers and mobile devices by user-friendly dashboard overviews and shared with the existing WMS. This ensures smooth material flow within the logistics centre. Briegel emphasises, “Dematic has fulfilled this order to our complete satisfaction. Throughout the entire process, the cooperation was collegial and on an equal footing. Most importantly, since we put the new logistics centre into operation, we have been much more efficient and flexible.”