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material flow PRODUCT OF THE YEAR 2024

Daniel Schilling,

Category 4: Hörmann Intralogistics - Cooling and room temperature AutoStore

A combined picking station at Flaschenpost. © Hörmann Intralogistics

The world's first micro-fulfillment solution with two combined AutoStore systems for dry and chilled goods for the online supermarket Flaschenpost.

For the innovative design of the AutoStore system, Hörmann Intralogistics combined the different temperature zones "Ambient" and "Chilled" in such a way that it is possible to pick dry and chilled goods from both systems at one workstation for one order. In the "Chilled" system, the AutoStore containers are stacked directly on the floor on 16 levels in a grid system measuring approx. 10 m x 40 m (L x W). 18 "Red-Line" robots move on the rail system (grid) in two directions with their four pairs of wheels arranged around the corners and thus reach every position on the grid.

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Technology and efficiency

They tirelessly pick up containers, store them, re-sort them and operate the ten conveyor ports, which are available for storage and picking. The scope of delivery also included the complete housing of the chilled system as well as the cooling technology to operate the system at +2°C. A specially adapted cooling system ensures minimal leakage during operation and optimum energy efficiency. Directly adjacent is the "Ambient" AutoStore system for items at room temperature in the Flaschenpost warehouse. Approx. 10,000 containers are available on 16 levels in the 8 m x 40 m (L x W) grid system. On the grid, 25 robots supply the eight carousel ports for retrieval and two conveyor ports for storage. Both areas come together at eight innovative combined work stations, each equipped with a carousel and an insulated conveyor port, an empty container and a full container conveyor system.

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The ready-picked flaschenpost transport crates are then transported directly to the delivery vehicle, which delivers them fresh and quickly to end consumers. The goods are received at conveyor ports attached to the side. Ambient - 25 R5 robots - 8 carousel ports - 2 conveyor ports (outside) for incoming goods - approx. 10,500 containers - dimensions: 9x40m Chilled - 18 R5 robots - 10 conveyor ports - approx. 8,500 containers - dimensions: 10x40m 8 combined workstations, each with a carousel & temperature-controlled conveyor port as well as conveyor technology for container delivery Other trades: - Conveyor technology - Cold room construction - Cooling technology - Steel construction.

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Unique selling points

- Worldwide unique arrangement of two AutoStore systems next to each other: one system operates in the ambient (+20°C) and one system in the chilled area (+2°C). - An employee station consists of a Carousel and an insulated Conveyor Port and thus enables an order from both temperature zones to be processed by a single operator.

- Coupled with a conveyor system, the order picker is optimally supported with target containers and achieves a particularly high picking efficiency.

- The delivery speed could previously only be achieved with a large workforce.

The following groundbreaking services are now possible: a. Removal of immediate orders in under 15 minutes b. Over 200 item picks per hour per workstation, more than tripling the picking performance c. 1,000 container deliveries per hour at peak, up to 12,000 items can be handed over to the flaschenpost delivery vehicles per day d. Performance growth possible up to over 20,000 items per day.

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