Tillmann Wellpappe has been producing all types of corrugated cardboard packaging since the 1960s. The spectrum ranges from folding cartons, die-cut packaging, sheet packaging and jumbo cartons to individual solutions. From fine microwave to three-wall heavy-duty corrugated cardboard, customers from various industries can find a packaging solution.

At the plant in Sundern-Stockum in the Sauerland region, corrugated cardboard sheets are produced and processed into finished packaging. To store the various finished pallets, the long-established Sauerland-based company placed its first order with Dematic's predecessor company Mannesmann Demag Fördertechnik in 1990. The finished packaging was temporarily stored for customers in the four-aisle automated high-bay pallet warehouse with 5,000 spaces after it had been checked for contours. After just nine years, these storage capacities were exhausted, making an expansion unavoidable: Six new aisles were added to the existing high-bay warehouse. The resulting capacity of 21,000 pallets in the automated ten-aisle warehouse with double-deep storage with the help of storage and retrieval machines initially seemed generously designed and more than sufficient. After all, the high-bay warehouse extends to a total height of 24 meters, with an aisle length of 65 meters. On peak days, up to 3,400 pallets are delivered. However, as customers ordered more and more individually printed packaging at short notice, the need for storage space increased.

According to the company, sustainability is firmly anchored in Tillmann Wellpappe's corporate philosophy. For example, the Tillmann paper mill in Zülpich-Sinzenich operates a combined heat and power plant, recycles waste water in a closed cycle and only uses waste paper, which is then transported to Sundern-Stockum in the form of three-ton rolls for corrugated board production. The ageing first-generation storage and retrieval machines were therefore not replaced, but modernized.

Maximum availability in the warehouse despite conversion

The modernization of six storage and retrieval machines began back in 2018. The all-round PC control system for all six stacker cranes was gradually replaced by a PLC control system for each individual stacker crane. This means that the stacker cranes can operate independently of each other in the high-bay warehouse and only the affected device needs to be switched off for modernization or subsequent repair work, while the others can continue to process other orders.

This ensures seamless storage and retrieval of products in the warehouse without downtime or losses. In addition, the travel and lifting motors as well as the motor for the load handling device of the storage and retrieval machines have been replaced. The new belt drives are more energy-efficient and all devices now have energy recovery during braking. The energy generated in this way can be made available to other devices or fed into the AC grid.

All devices have also been revised in terms of safety and equipped with an operating terminal. Cameras installed on each device allow remote monitoring of the load handling attachments, help to localize and rectify faults and open up opportunities to reduce time-consuming work at great heights. Fieldbus Interbus-S was replaced with the more modern Profinet. During the measures, the old interfaces to the conveyor technology and the material flow computer were also taken over, allowing the new technology to be seamlessly integrated into the existing system. Thanks to Dematic's high level of expertise in its own storage and retrieval machines, once the modernization is complete these will be largely technically identical to the new storage and retrieval machines that will be used in the expansion of the high-bay warehouse. The solution is therefore more sustainable and cost-efficient than the complete replacement of the stacker cranes.

Almost 4,300 additional pallet spaces

For the expansion, over 40,000 cubic meters of soil were removed from the existing high-bay warehouse at Tillmann Wellpappe in Sundern-Stockum. The three new aisles with double-deep Dematic racking are already in place. Construction began at the start of the year. After completion, a total of 4,284 more pallet spaces will soon be available here. The existing Dematic conveyor technology for heavy unit loads will be extended for the storage and retrieval aisles and the connection between the new and old systems will be established. It will soon be possible to pre-produce and store even more customized printed corrugated board packaging, special formats and closure solutions. Storage and retrieval is carried out using three new Dematic RapidStore SR-U1200/1 storage and retrieval machines with double-deep telescopic forks. Both the new and modernized storage and retrieval machines and the additional conveyor technology in the pre-zone are integrated and all visualized by a Dematic control system.

Availability for at least a decade

The modernization and expansion project will be rounded off with a service and maintenance contract adapted to the new scope. With 24/7 availability of Dematic employees and preventive maintenance measures, Tillmann Wellpappe will then be able to rely on a guaranteed system availability of 98 percent. In addition, both software and spare parts availability will be contractually guaranteed for ten years.

There are further synergy effects: the modernized equipment is largely identical to the new storage and retrieval machines, which results in further advantages in terms of integration and spare parts inventory. However, if a spare or wear part is not available, Dematic will procure compatible parts or offer alternative solutions in order to maintain the full functionality of the system.

Published in materialfluss SPEKTRUM 2021.