Due to many years of sales growth, the previous logistics structures with several external warehouses within a radius of 70 kilometers had reached their limits. The centralization of all logistics activities enables significant_CO2 savings due to the elimination of transport as well as a considerable increase in storage capacity and efficiency. Particular attention was paid to sustainability and the most inconspicuous integration possible into the surrounding Alpine landscape.

The capacity expansion is essentially based on three elements: The fully automated processing of empties returned from the beverage trade, which are placed on the pallet inspection and exchange system. A 42-metre high and 76-metre long, 6-aisle high-bay warehouse, which is connected to all production facilities and loading via electric monorail systems. The entire process is controlled by the SitePilot Warehouse Management System from System Logistics GmbH, which communicates directly with the ERP system and yard management.

The solution enables complete automation of all intralogistics processes, from empties, which are placed on a pallet inspection and exchange system, to the supply of empties to the production facilities, production disposal in the high-bay warehouse and the connection of loading via an electric monorail system. The overall system ensures maximum availability and efficiency for the approximately 850,000 pallets that leave the plant in Siegsdorf every year.

The project was realized by System Logistics GmbH as general contractor.

The facts:

• Fully automated, double-deep, 42 m high high-bay warehouse with 6 aisles and approx. 23,700 storage locations Capacity: 138 (315) pallets in & (out) / hour
• 6 storage and retrieval machines with 2-fold load handling devices, energy recovery units and power-dependent reduction
• Fully automatic pallet inspection and exchange system: 5 pallet exchangers, 4 pallet inspection devices
• Conveyor technology & transfer car for empties supply to the directly connected sorting and filling systems
• Direct production connection via an electric monorail running above the production building
• Disposal of filling systems: ~ 600 pallets / hour
• Block storage supply: ~ 300 pallets / hour
• Direct loading connection via an overhead monorail system
• 24 buffer lanes for rear loading and conveyor connection for side loading
• Capacity: 300 pallets / hour
• SitePilot Logistics Execution Software Suite
• SCADA system visualization

The challenges:

• Stock takeover / system changeover in just one weekend during ongoing operations
• Expansion of storage capacity without increasing space requirements
• Integration of the entire value chain

Adelholzener Alpenquellen
Adelholzener Alpenquellen GmbH, based in Siegsdorf, produces medicinal water, mineral water and soft drinks under the brands "Adelholzener" and "Active O2". The company fills around 580 million bottles a year and exports them to more than 20 countries. Adelholzener Alpenquellen employs around 600 people and belongs to the Congregation of the Sisters of Mercy of St. Vincent de Paul. The congregation finances its social projects with the company's proceeds - unless they are needed for investments to maintain long-term jobs at Adelholzener Alpenquellen.