Efficiency and reliability

The foundation stone for CG-Chemikalien was laid more than 50 years ago in Laatzen near Hanover. To date, CG has continued to develop and establish itself in numerous markets, so that its customers now include around 5,000 companies from the pharmaceutical, automotive, chemical, electronics, plastics, food and foodstuffs sectors. With an annual tonnage of around 105,000 tons, an operating area of 55,000 square meters and an annual turnover of 83 million euros, CG-Chemikalien GmbH & Co KG is a mainstay of the German chemicals trade. The company's customers are supplied just-in-time 365 days a year using the company's own trucks.

Stacker pick-up point with placement aid and destination selection. Photo: HaRo

With a corresponding average stock level of around 7,500 tons, the logistics space at the Laatzen site was ultimately tight. In order to meet the growing demands of the pharmaceutical industry and the associated high requirements for material flow and conveyor technology concepts in the future, a new solution had to be found in 2015: The idea for one of the largest new construction projects in the history of the CG Chemicals Group was born; this also included the installation of a fully automated pallet conveyor system.

Intelligent conveyor technology concept

In order to transport the chemical and pharmaceutical products stored on aluminum and plastic pallets directly from their filling to their storage, the CG-Chemikalien Group was looking for a conveyor technology concept. The company was also able to clearly define the requirements: The transport system had to be a flexible system that would meet the specifications of the logistics center's clean rooms and at the same time be able to transport a wide variety of pallet designs without any problems or disruptions.

"For CG, the investment proved to be forward-looking, as production output could be significantly increased."

In its search for suitable material flow technology, the CG Chemicals Group turned to HaRo Anlagen- und Fördertechnik GmbH in Rüthen. With its headquarters in Rüthen, HaRo is one of the regional economic pillars in the Sauerland region. The conveyor technology manufacturer integrates individual logistics solutions with a high degree of automation into production and warehouse environments. According to HaRo Anlagen- und Fördertechnik GmbH, the company stands for robust and stable machine technology that is characterized by a long service life and economic efficiency. The in-house production of system controls completes the solutions from a single source. The Rüthen-based company impressed CG with a well thought-out, flexible solution and recommended the use of an efficient roller conveyor system that transports the goods to their destination fully electronically.

Convenient destination assignment from the forklift

Adjustable side guide with internal VA profile. Photo: HaRo

The HaRo system serves as a coordinator for transportation between the raw materials and semi-finished goods warehouse, filling and weighing in the clean rooms and transport to the finished goods warehouse and/or back to the semi-finished goods warehouse. In principle, two parallel lines with bypasses were installed for this purpose. After the goods have been loaded into the HaRo system by forklift truck, the pallet barcode is assigned to the destination using a radio scanner - conveniently directly from the driver's seat of the forklift truck. The CG management system ensures error-free destination coordination; destination tracking is thus guaranteed via a HaRo data interface.

Directly after feeding, the transition from the gray area to the white area takes place using a gate/lock combination in an overpressure process. This meets the high requirements for product safety and cleanliness. The four filling stations are approached via rotary stations. An additional high-speed door in front of each station prevents contamination of the adjacent areas. The recipe is weighed at the filling station and loaded into the transported goods. After completion, the pallet leaves the clean room and is transported by destination tracking to the finished or semi-finished warehouse, where it leaves the HaRo system with a forklift truck.

Interfaces are monitored and integrated

Walk-on roller conveyor in the clean room for loading the workpiece carriers. Photo: HaRo

"As CG-Chemikalien GmbH & Co. KG is a distributor that primarily stores chemical or pharmaceutical products, there are many special features to consider," explains Managing Director of the HaRo Group Christoph Hackländer with regard to the planning and production of the system. For example, stainless steel support rollers with flange guides were used and the frames of the system were permanently powder-coated. At the interfaces to the forklift truck, special stainless steel centering devices were designed for precise but also fast and uncomplicated interventions. Special protective plates on the motor fans prevent dust turbulence. Wide overhanging and horizontal surfaces as dirt traps had to be avoided. Roller covers on the conveyors, on the other hand, provide protection and safety for employees.

A modern and flexible conveyor control system regulates all processes and visualizes all system statuses. All interfaces are monitored and meticulously integrated. Remote analysis is possible via Ethernet. "We are always happy to take on such challenges," emphasizes Christoph Hackländer. The installation was carried out by the team from HaRo Anlagen- und Fördertechnik GmbH and the start-of-production deadline was met in full by the conveyor technology experts from Rüthen. For CG, the investment proved to be forward-looking, as production output was significantly increased.

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