The international logistics service provider Grieshaber Logistik has invested in a new logistics center in Cologne with an area of almost 8,900 square meters and a capacity of around 9,600 CP3 pallets. Among other things, Grieshaber specializes in designing and implementing individual logistics solutions for industrial and retail customers. In the current project, the warehouse in the existing building was to be equipped with conveyor technology and connected to the new logistics center for a customer from the chemical industry. The aim was to automatically and efficiently distribute the goods from production to the various pick-up points in the existing building and the new building. The goods to be transported are CP3 chemical pallets made of wood or plastic with a maximum weight of 1,400 kg. A suitable material flow concept was developed and implemented in collaboration with Grieshaber Logistik.

Breathing intralogistics

The objectives of the conveyor concept: The buffer capacity was to be expanded to allow the entire system to "breathe" during different working hours in production and logistics. In addition, a second conveyor line was to be integrated from the existing hall in the direction of the logistics center. The integration of a further pallet removal system in the new hall with target management in the PLC for the two logistics halls and the bridging of the gas line area by means of a conveyor bridge that can be quickly dismantled were also on the agenda.

First, the existing retrieval line was extended to include a turning device with an integrated shifting unit, which takes over the function of direction preselection. Parallel to the existing retrieval line with picking station, an additional storage line with a feeding station was installed in order to transfer goods from here to the logistics center on the new conveyor line.

Goods from production reach the turning device with transfer unit via the existing conveyor line. Here it is decided whether the pallets are transported straight into the logistics center or to the right to the retrieval section of the existing hall. For this purpose, the pallets are provided with barcodes in which the respective destination is coded item-specifically. The destinations are managed via a PLC control system. In the direction of the logistics center, the new approximately 110-meter-long roller conveyor line connects the existing building with the adjacent logistics building via a removable conveyor bridge.

Dismountable conveyor bridge

The conveyor section between the existing and the new logistics building is a special feature. Here there is an approximately eight meter wide protective strip of a gas pipeline. In this area, an easy-to-dismantle conveyor section was commissioned, which was designed in compliance with official regulations. The conveyor bridge was designed as a covered steel structure with side cladding. The construction, which is 15 meters long in total, can be completely dismantled in an area of eight meters with a forklift truck in just 30 minutes if access to the gas pipeline is required. Sectional gates are fitted at the entrance and exit of the bridge, which open and close automatically as soon as conveyed goods pass.

Buffer capacity offers flexibility

To ensure the greatest possible buffer capacity and to absorb fluctuations or malfunctions, the entire conveyor line is designed for pallet accumulation. On the 4.5-metre-long roller conveyor elements, three pallets form a cluster with a maximum total load of 4.5 tons.

The advantage of the buffer is particularly evident at weekends, when finished goods from production are buffered on the conveyor line and can only be distributed to the warehouse or logistics area on Mondays. Up to 90 pallets can then be prepared for removal.

Reliable control and integrated safety concept

The conveyor system is controlled via a Siemens S7 safety PLC and the system is networked via Profinet. The FAB service team can access the system at any time via VPN. Manual operation is organized with a mobile panel, distributed over 12 plug-in points on the conveyor system. Each drive is equipped with a Movimot and integrated into the bus system.

The system was integrated into the existing safety concept. Along the conveyor line, there are two crossovers that are secured by light barriers and allow employees to cross safely if necessary.

The installation of the complex system was carried out during ongoing operations. In order to keep the decommissioning of the existing plant as short as possible, the implementation was carried out in two construction stages. The project was successfully completed with the commissioning and handed over to the client. In order to maintain the performance and availability of the system in the future, maintenance and accident prevention inspections are carried out annually by FAB service personnel. VPN access to the control system allows an up-to-date view of the system at any time. Direct intervention can also be carried out quickly and easily if required.

Gregor Schnell, Managing Director of Grieshaber Logistik, sums up: "The project took just six months from the planning phase to implementation and commissioning on site. Thanks to FAB's well thought-out concept and the close and effective coordination with all the trades involved, the project ran smoothly.

The article appeared in materialfluss 11-21/21.