Clear conversion concept from PROMStahl

For the company EGU Elektro Grosshandels Union Rhein-Ruhr, based in Dortmund, the time had come to decide on a new investment, especially as the company's growth and the challenges in terms of fast delivery times required an optimization of all logistics processes involved. The decision was made to switch to a new warehouse management system, to expand the incoming and outgoing goods areas and to modernize the existing warehouse areas, including the connection to a new WMS. Another conversion measure planned was a more effective loading zone. It was to be tailored to the different vehicles and, above all, work much more energy-efficiently. New building or conversion - that was the key question. The decision was made to rebuild. The location for the central warehouse was ideal, and the building fabric largely met the requirements and, ultimately, agiplan's concept also promised considerable budget savings.

Interior view of an airlock with profile-reinforced trapezoidal sheet metal construction.

Loading technology creates storage space The entire process at the ramp/truck interface was put up for discussion. In particular, the requirement to gain more space in the hall in front of the dock levelers for maneuvering and order picking called for a new concept. All the old loading ramps were designed as internal ramps and therefore took up space in the hall. The planners at agiplan therefore called in loading specialists right from the start. Dipl. Ing. Peter Wunderlich, agiplan, and Michael Stausberg, Managing Director of EGU, said in unison: "The professional quality of advice combined with the expertise gained from numerous reference projects led us to choose the loading specialist Promstahl for this task."

The main requirements for Promstahl were the removal of the old loading technology while at the same time gaining space in the hall and a loading concept that had to take into account the issue of energy costs at the ramp/truck interface. The topic of energy saving in particular demanded a tailor-made solution for the wide variety of truck types that had to be handled here in Dortmund.

Example of sprinter handling

The narrow and low Sprinter delivery vehicles in particular, which are used for deliveries here, usually stand in the way of effective sealing during the loading process. A very low loading height and smaller external dimensions in height and width are the weak points that neither door sealing nor loading technology can usually solve satisfactorily. An efficient solution, especially in terms of sealing, required a special solution. A similar problem arises with the loading technology. As a result of its considerations, Promstahl installed swivel dock levellers in conjunction with an unusual weather protection variant. These mechanical loading systems, attached to the front edge of the ramp so that they can be moved sideways, are ideal for loading

Ideal for low Sprinters of the low Sprinter. In contrast to stationary dock levellers, spring elements located under the plateau allow them to rest practically weightlessly on the loading area of the Sprinter. Promstahl solved the task of efficient sealing with a rather unusual version. They reached a little deeper into their bag of tricks and fitted the Sprinter docking points with loadhouses, which were set up directly at yard level and fitted floor-to-ceiling tarpaulin aprons in the front area - actually a solution for niche installation on on-site concrete porches. This means that the Sprinters are protected from the weather for almost the entire length of the loadhouse during the loading process and are also sealed at the sides and from above over their entire height.

Advantage space gain

Fastening the swivel bridges to the edge of the ramp.

Although the entire facility was gutted and adapted to the increased logistics requirements with new storage equipment, one problem remained unresolved: additional space was needed in the loading zone, which had previously been taken up by internal dock levellers. Promstahl pointed out the advantages of external ramps in conjunction with loadhouses. Although the plan was to replace the old dock levellers with new ones, the decision was made to move the entire loading technology to the outside due to the additional space required in the hall. In this way, additional storage space was gained without much effort or cost. Another requirement of the EGU was met by the loadhouses: compliance with energy guidelines. The advantage of the completely external loading technology is the thermal separation of the building and the loading technology.

Five new loadhouses including attachment ramps were placed under an existing canopy. For the hydraulic dock levellers, the decision was made to use the tried and tested feed technology. The advantage lies in the optimum adjustment, even for trucks that dock inaccurately. The docked trucks are sealed by a mechanical tarpaulin door seal with lifting roof and parallel steering system.

The package was completed with an internal and external vehicle recognition system, which works with the help of an LED traffic light system as a docking aid plus a safety wheel wedge with ultrasonic sensor. In contrast to the Sprinter docking points, only trucks of the usual sizes are handled at the five loading points. In terms of special services, Promstahl dismantled and disposed of the old loading technology and installed a ramp head reinforcement for the new swivel dock levellers.

Contact:EGU Elektrogroßhandels Union Rhein-Ruhr GmbH & Co. KG 44309 Dortmund Tel.: 02 31 / 2 29 09-0 E-Mail: [email protected] www.e-g-u.de

PROMStahl GmbH 30989 Gehrden Tel.: 0 51 08 / 87 92 70 E-Mail: [email protected] www.promstahl.com