Download Unitechnik builds automatic distribution hub for Macromex

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Unitechnik builds automatic distribution hub for Macromex
Europe's tallest deep-freeze storage warehouse
A height of 42 meters is quite a feat for a logistics property. To
support optimum processes at a temperature range of +4 to -24
degrees Celsius, a truly sophisticated logistics concept is needed.
One good example is the Macromex distribution hub in Cȃmpia Turzii
– “Edenia Distribution Center”. The Romanian frozen-foods supplier
has built a new distribution hub at this location together with
Unitechnik as system integrator. Macromex delivers on time to
international customers from this automatic high-bay racking store
with 17,000 pallet locations. The € 17m project is capable of handling
up to 2,000 pallets per day.
6,450 m² under-roof floor space, 42m height and temperatures of down to
‑24 degrees. The specifications of the new Macromex distribution hub in
Cȃmpia Turzii are impressive. The location is the logistic key point for the
largest frozen goods supplier on the Romanian market. Given the rapid
increase in demand for frozen foods, Macromex decided in 2009 to
centralize their regional warehouse and to bundle capacities. "The
requirement was to build a state-of-the-art logistics hub for frozen products
that meets both current as well as future requirements in regard to
technology and efficiency," reports Dan Minulescu, Macromex CEO. No
sooner said than done: Strategically located between Bucharest and
Budapest, the frozen-foods specialist has chosen the site for storage, order
picking and shipment of their own Edenia, La Strada and Corso brand
products as well as for third-party products from La Lorraine Romania, Dr.
Oetker and others. The range of goods stocked includes frozen foods from
vegetables to meats and baked goods to ready-made meals and ice cream,
and they are shipped from Cȃmpia Turzii throughout Europe. Both the
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sensitive stored products as well as delivery times of 24 h maximum make
particular demands on internal logistics.
Mastering the challenges of logistics
The main challenge in designing the distribution hub was fast and smooth
process sequences. Consequently, all warehouse and function areas are
linked in such a way that paths are as short as possible. This concept was
developed by the planning office Metroplan Eastern Europe. Unitechnik
was then commissioned with building the logistics facility as general
contractor for the racking structure, the conveying system, the automatic
cranes and the warehouse’ control system. Unitechnik, the logistics expert
from Wiehl, Germany, and Knapp AG customized the work processes
specifically to frozen food logistics staff and their application requirements.
Following delivery by truck, a worker scans the pallets at the receiving point
set up specifically for the load and cooled to -24 degrees. The data are
entered in the warehouse management system (WMS) supplied by Knapp
AG. Depending on the product group, use-by date or batch number, the
WMS assigns the pallet a stock location. The WMS also differentiates
between refrigerated and deep-freeze sections. In the refrigerated section,
the so-called 'chilled area', Macromex primarily stores fresh produce. There
are approximately 700 bin locations available in a forklift-managed high-bay
racking store. The temperatures in this section are between +2 and +4
degrees. Goods are stored here temporarily, picked to order and packaged.
Pallets destined for the -24 degree automatic high-bay racking store are
directed by Macromex workers onto a conveyor system designed by
Unitechnik for these low temperatures. Approximately 250 optical sensors
along the path check whether the pallets comply with warehousing
requirements or are defective as the case may be. If a pallet does not meet
the requirements, the system immediately diverts it out of the flow - entirely
managed by the WMS. Once a pallet has been reloaded and relabeled, it
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proceeds to the high bay warehouse. It is the heart of the new logistics hub
and at 42m is Europe's tallest automatic deep-freeze storage warehouse.
With only three aisles, it still has 17,000 Euro pallet storage locations.
Pallets are stored double-deep on 16 levels so that space is optimally used.
The storage and retrieval on each aisle is served by a 40.5m high singlemast rail-guided stacker crane from Dambach Lagersysteme GmbH & Co.
KG.
Order picking made easy
In order to meet fire safety requirements, the high-bay racking store is an
inert warehouse, meaning that the oxygen content is only 16% comparable to an elevation of 4,000m above sea level. Order picking thus
takes place outside of the system in the order picking and staging area also
cooled to -24 degrees. Once a pallet is retrieved, it is automatically brought
to this area by the conveyor system. High-speed gates between the high
bay warehouse and the order picking area ensure that the different oxygen
concentrations are maintained in both areas. Orders are picked using pickby-voice technology from the company Vocollect. Macromex differentiates
between fast-moving and slow-moving commodities. A and B articles are
picked according to a man-to-goods principle. Via their headsets, pickers
are instructed which products are to be taken out in what quantity. The
WMS guides them to the corresponding order-picking station along the best
path. "Macromex stages C articles at a dynamic picking station connected
to the conveyor system. Articles are picked according to the goods-to-man
principle," Martin Rauer, Project Manager from Unitechnik, explains.
Macromex also uses the automatic warehouse to replenish fast-moving
areas as well as for full-pallet retrieval. The system's handling rate is up to
2,000 pallets per day.
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Cool. Cooler. The coolest.
An important criterion when planning the new distribution hub was
maintaining the cold chain. The refrigeration concept developed is a
reflection of it. To preserve the cold inside in winter and to keep heat out in
summer, the building was equipped with individual insulating panels each
13m long. Inflatable door seals at air locks at shipping and receiving
minimize heat exchange and humidity. In addition, truck loading and
unloading may take no longer than 27 minutes to preserve the cold chain.
Temperatures also place high demands on the technical installations.
Particular attention was placed on the high-bay racking store. To prevent
sub-floor freezing, a heated base plate was used as frost heave protection.
Due to the temperature fluctuation this causes, the steel structure has to be
designed to expand and contract without losing stability. “The cooling
concept also takes the human factor into account. To comply with strict
safety requirements, our employees may only enter the frozen areas of the
logistics hub in appropriate clothing," emphasizes Dan Minulescu. "They
also always work in pairs in the High-Bay location, for technical
maintenance. Cameras and walkie-talkies ensure that help is only a push of
a button away in an emergency."
More than just a strategy
About five years - from the initial planning to start-up - is how long it took
until the new Macromex distribution hub opened. And it was worth the wait.
In adopting this logistics concept, the frozen-food logistics supplier
optimally meets customer requirements. At the top of the list: one-day
delivery throughout Europe as well as the ability to supply individual
customer requests. The frequency of deliveries and use-by dates play an
important role. Macromex guarantees, for example, that later deliveries to a
customer will also always have a longer use-by date. A customer-focused
concept that promotes further growth. Macromex expects business to
expand over the next few years thanks to their present logistics
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competence. An expansion of the logistics hub that would double capacity
is just as feasible as a new "greenfield" building.
Status:
10 March 2016
Length:
7,749 characters (incl. spaces)
Images:
Image 1:
Macromex Edenia Distribution Center at night.
Image 2:
Macromex Edenia Distribution Center at daytime.
Image 3:
Automatic high-bay racking store with 17,000 pallet locations.
Image 4:
In the refrigerated section for fresh produce there are
approximately 700 bin locations available in a forklift-managed
high-bay racking store.
Image 5:
Following delivery by truck, a worker scans the pallets at the
receiving point set up specifically for the load and cooled to 24 degrees.
Image 6:
Macromex CEO Dan Minulescu
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About Unitechnik
Unitechnik Systems GmbH with headquarters in Wiehl has been one of the leading suppliers
of industrial automation and information technology systems for four decades. The secondgeneration family business designs and produces bespoke systems for internal logistics
cargo systems, and production. Unitechnik conducts business worldwide as a system
integrator and single-source supplier. Professional project management as well as
competent customer support of finished installations are the foundation of long-term
business relationships and safeguard the customer’s investment. The group has locations in
Germany, England, Dubai, Switzerland, and Australia. Included among Unitechnik’s
references are such well-known companies as BMW, Emirates, LSG Sky Chefs, Celebi and
Spirit Air Cargo.
Corporate Contact Unitechnik
Wolfgang Cieplik • Unitechnik Systems GmbH
Fritz-Kotz-Str. 14 • D-51674 Wiehl
Phone: +49 (0)2261 987-208 • Fax: +49 (0)2261 987-510
E-Mail: [email protected] • Internet: www.unitechnik.com
Media Contact Agency
Stefanie Schoebel • additiv pr GmbH & Co. KG
Pressearbeit für Logistik, Stahl, Industriegüter und IT
Herzog-Adolf-Strasse 3 • D-56410 Montabaur
Phone: +49 (0) 26 02- 950 99-20 • Fax: +49 (0) 26 02- 950 99 -17
E-Mail: [email protected] • Internet: www.additiv-pr.de
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