As one of the leading companies for nutrition, infusions, pharmaceuticals and medical products, Fresenius Kabi places high demands on its logistics. The fully automated high-bay warehouse built by Kardex Mlog at the Friedberg site in 1996 has been continuously expanded, modernized and developed into an international logistics center with an area of 16,500 m² and around 75,000 pallet spaces.

In the current project, which was completed in March 2020, several existing hall areas were connected via a new picking area and a building extension, and the processes in the warehouse were reorganized. Kardex Mlog was awarded the contract for the expansion of the conveyor technology, including the control system, the adaptation of the existing visualization system and the connection to the customer's warehouse management system and material flow computer. "The combination of logistics expertise and precise knowledge of our location and our requirements profile from previous projects were important reasons for once again relying on our long-standing partner Kardex Mlog," says Peter Hubl, Head of Logistics Technology at Fresenius Kabi Logistik GmbH. After the extension, the different hall areas could be connected across all levels with a likewise new, on-site picking area. Kardex Mlog added new conveyor technology to the existing system with two loading and unloading stations, continuous conveyor technology, a distribution trolley and two vertical transfer units.

Seamless integration into the existing building

The vertical transfer units installed above the roof serve all floors and can each transport around 110 pallets from the first floor to the second floor at a maximum lifting speed of 80 m/s per hour. The distribution trolley installed there achieves an output of 120 pallets per hour at 100 m/s. This means that the new components fit perfectly into the existing environment, whose throughput has not been changed.

Kardex Mlog completely rebuilt the conveyor technology downstream of the vertical transfer units on the upper floor. On the first floor, the existing distribution trolley was connected to both transfer units by extending the travel path. A new delivery station was also installed. On the first floor, the connection to the existing conveyor system to the high-bay warehouse was made by integrating turntables.

Higher degree of automation and optimized conveyor lines

Thanks to the new layout of the conveyor technology, the previously largely manually supported material flows could be automated to a greater extent and shortened between the floors. "Thanks to the optimized routes and the higher degree of automation, Kardex Mlog was able to achieve a significant increase in efficiency and throughput without having to implement performance-enhancing measures on the existing system," concluded Peter Hubl at the commissioning in March 2020, "we see the effort and result in an ideal ratio."