Those responsible at Dr. Kurt Wolff - a cosmetics manufacturer known for brands such as Alpecin, Plantur and Alcina - particularly appreciate the partnership-based, solution-oriented approach to their collaboration with Förster & Krause, even when it comes to minor adjustments to existing products. "Förster & Krause listens, thinks along with us and develops solutions that are not off-the-shelf, but fit in perfectly with our processes and operations," says Andreas Wiens, Technical Director of the Dr. Wolff Group. In a building that has grown over decades, the old technology was completely replaced by a new pallet conveyor system, which was implemented during ongoing operations. One of the main objectives was to connect the basement in order to bring raw materials into production more efficiently and to sustainably improve the internal material flow.

Vertical conveyors for pallets and IBC containers

The new conveyor system connects the basement, first floor, 1st and 2nd floors via a central vertical conveyor, designed for up to 40 pallets per hour. It transports Euro and industrial pallets as well as IBC containers weighing up to 1,500 kg and works flexibly and reliably. Each level has loading and unloading stations with upstream conveyor sections and accumulation stations, tailored to existing processes and space conditions. Loading is carried out manually using a tiller or forklift truck, with the system taking over control. The operator selects the destination conveniently using a pushbutton on the task. The touch panel displays whether the selected floor is occupied or free. This information is only used for orientation purposes, as the system only starts conveying if there is free space at the destination.

Efficient material flow thanks to intelligent control and free-space logic

A central element is the free space check with transport release: the pallet is only conveyed if a free stowage space is available on the selected destination level. Using touch panels on each floor, operators can immediately see which destinations are currently available - and can prioritize flexibly. The system prevents empty runs, increases the conveying capacity even with high capacity utilization and dynamic requirements and ensures smooth pallet transport between the floors. The control system not only supports the process, but also the employees, who can work clearly and efficiently.

Conveyor technology integrated in existing buildings with limited space

The structural conditions: normal ceiling heights, ongoing production, clearly defined traffic routes. The challenge: integrating fully-fledged pallet conveyor technology under these conditions without disrupting processes or blocking areas. Robust chain and roller conveyors are used, which offer both high performance and a long service life. The entire conveyor section is reversible and adapted to the weight and dimensions of the goods to be conveyed. The result is a compact solution that takes existing routes into account and is also designed to be future-proof.

The new technology is part of a comprehensive, long-term change process. "With every modernization, we notice how much smoother and clearer our processes become. We don't just replace old with new, but scrutinize the process. F&K is following this path, step by step," says Andreas Wiens, who was also responsible for the retrofit of the conveyor technology in the automated high-bay warehouse last year.
Realized in partnership - with a view to further modernizations

The successful implementation is based on closely coordinated project work on both sides, from the initial concept idea through to commissioning. All the work - from the dismantling of the old conveyor technology to the necessary ceiling breakthrough to the basement and an additional wall breakthrough to the subsequent installation and commissioning - was perfectly coordinated. This meant that the system could be used again after around three weeks, which was also appreciated by the customer.
Förster & Krause has an equally positive view of the collaboration: "The projects with Dr. Kurt Wolff are always based on partnership, clearly structured and targeted. It is a customer with whom we like to think ahead together," says Hans-Georg Förster, partner and logistics planner at Förster & Krause. Further retrofits and new systems in the area of conveyor technology are already being planned, with the aim of gradually making the internal material flow more efficient, transparent and resilient.