Emmi is the largest milk processor in Switzerland and is considered one of the most innovative premium dairies in Europe. Headquartered in Lucerne, the company exports its products to 60 countries worldwide. Fresh products such as yogurts, Emmi Caffè Latte and ice cream are produced in Ostermundigen near Bern, where they are also temporarily stored. In addition, products from other production sites are also transported using the cross-docking process. The annual throughput amounts to around 350,000 pallets of chilled goods and around 65,000 pallets of non-chilled goods. In addition, there are around 30,000 pallets of retail products.

Storage capacity increased to 8,600
For many years, Emmi operated two high-bay warehouses in Ostermundigen, one for fresh products and one for frozen products. Due to continued growth, the decision was made at the end of 2013 to outsource frozen logistics and convert this high-bay warehouse into a logistics hub or fresh distribution center. In addition to technical building measures, this required a redesign of the internal material flow and distribution logistics. As a result, Emmi commissioned Stöcklin Logistik to implement the upcoming tasks as general contractor for intralogistics. In the course of this, between 2013 and 2015, the existing channel warehouse was rebuilt and the storage capacity increased to 8,600 spaces.

Data communication standardized and transports automated
Since then, there were practically two independent warehouses, each with their own warehouse management and material flow control systems. In order to achieve a new, interface-optimized consistency for both systems, the control sovereignty for all material flows was completely transferred to the StöcklinWCS. This module functions both as an integral component of the Stöcklin WMS or, as in the case of Emmi, can be operated as an independent level below the WMS of a market competitor. At the same time, functional adjustments were made to the conveyor technology and the transportation of goods between the two warehouses was automated. "In view of the continuous improvement process implemented at Emmi, feeds using hand pallet trucks or forklifts were no longer tolerable," reports project manager Niklaus Schäfer. Around 300 pallets have to be moved here every day over a period of twelve hours. In addition, there are around 200 manually picked pallets that have to be brought into the warehouse.

In order to master this more efficiently, the decision was made to use two automated Eagle ANT mid-lift devices from Stöcklin Logistik. The automated guided vehicles (AGVs) are characterized by the fact that they navigate using environmental features such as walls or pillars. Two integrated safety laser scanners provide the necessary orientation and continuously monitor the driving area. During the journey, the measurement data from the laser scanners is compared with a stored map of the operational environment in which the course is noted. In the event of mobile or stationary obstacles, the vehicle stops or adapts its speed to the situation. The automated guided vehicle system (AGV) is equipped with maintenance-free lithium-ion batteries (Stöcklin Li-Ion).

The output or number of transports by the AGVs is 25 pallets per hour at peak times. Over a period of twelve hours, an average of 300 to 500 pallets are now moved automatically, meaning that employees who were previously involved in this process can be deployed productively in other areas. "Thanks to its technical optimization, the Eagle ANT is designed for a quick return on investment (ROI)," says Bernd Krebs, Product Manager for AGVs/ AGVs at Stöcklin Logistik AG. "Users benefit from a high degree of flexibility thanks to navigation using environmental features, especially when route changes are required or additional vehicles need to be integrated to expand the fleet."

Complete package reduces costs and increases flexibility
"The physical connection of both warehouses by means of automated guided vehicles with simultaneous synchronization of the entire material flow control requires very special expertise, which we bundle in our Systems and Industrial Trucks divisions," says Bernd Krebs, describing the special requirements profile. "A consistently harmonized IT landscape across both high-bay warehouses makes many things easier, reduces interface problems and lowers support costs," adds Niklaus Schäfer from Emmi. Thanks to the implementation of the Eagle ANT-FTF, goods transports between the two high-bay warehouses can now be handled automatically, reliably and without errors. Stock transfer processes can also be handled flexibly, as the AGVs are always available and no employees need to be scheduled. Should an increase in capacity be required in the future, Emmi can easily add one or more autonomous "colleagues" to the existing duo at any time.