Klinkhammer picks up speed with digitalization at the WKS Group

The new dispatch warehouse will significantly increase the storage area and secure the growth of the WKS Group with a capacity buffer. At WKS, everything revolves around web offset printing in long runs. A 160-page printing press was put into operation back in 2013; on May 2, 2017, another 160-page press and the world's first 120-page press were put into operation at the Wassenberg site. In 2015, the WKS Group was the first web printer to be awarded the Blue Angel.

Goals and requirements for the automated warehouse

"In 2016/2017, we are investing around 40 million euros in production facilities and logistics. With the new warehouse, we are significantly increasing storage capacity and replacing manual processes in the block warehouse with automated processes in order to further improve logistics quality and efficiency," explains Dr. Ralph Dittmann, Managing Director of the WKS Group. Sebastian Schmitz, Project Manager at the WKS Group, adds: "When processing around 275,000 tons of paper per year, structured processes, sequenced retrieval for extensive truck route planning and a networked WMS are essential. The automation solution also significantly increases process reliability and performance in the dispatch warehouse." With the warehouse solution, designed by the Klinkhammer Group and implemented by autumn 2017, the WKS Group is pursuing the goal of combining economic and ecological requirements.

Due to the high growth rates, an automated, 4-aisle pallet high-bay warehouse is planned to provide the necessary storage capacity and performance. The conveyor connection to the existing building is via a bridge. With a pallet loading height of one to two meters, a total of 10,272 storage locations are available in the double-deep high-bay warehouse, which can retrieve up to 160 pallets per hour. With the space-saving, cost-optimized silo design, the thermally insulated façade is mounted directly on the racking.

Route provisioning and sequenced retrieval accelerate shipping

The WKS Group handles the distribution of the print objects. Thanks to sequenced retrieval from the high-bay warehouse, the pallets belonging to a truck tour are already provided in the correct order. Digitization and automation offer considerable savings potential here. WKS can also intervene manually to respond to short-term customer requests, such as combining several tours into one. An industrial road between the new warehouse and production building is covered by a conveyor bridge. The pallets coming from production are transferred to the conveyor system at a double-deep feeding station close to the floor. This means that two pallets can be loaded at the same time with one pallet truck or forklift drive. The pallets are then transported over the bridge to the high-bay warehouse using accumulating roller conveyors. A parallel conveyor line is also provided for the return transport of pallets. The goods issue is automated via 18 gravity roller conveyors, each with eleven pallet spaces. A high-performance cross-distribution trolley moves the pallets quickly along the staging lanes to the dispatch area.

Control center in the automated warehouse

New dispatch warehouse for WKS Druckholding GmbH in Wassenberg. Automated, 4-aisle pallet high-bay warehouse with conveyor connection to the production building and dispatch. Photo: Klinkhammer

"The warehouse management system is at the heart of the automated warehouse, enabling it to fulfill the complex and time-critical tasks that arise in a large print shop like WKS. It networks the entire warehouse and dispatch operation with production," explains Frank Klinkhammer, Managing Director of the Klinkhammer Group. The warehouse management system KlinkWARE is linked to the ERP system via an interface and receives internal product, route and transport tasks. KlinkWARE optimizes and coordinates the tasks to be completed and transfers the transport orders to the material flow control system.

Remote maintenance, hotline and on-call service

To support the automated warehouse technology and warehouse management software, including the material flow computer, Klinkhammer has specialist personnel available for training, system support, control technology and software support. At the same time, a 24/7 hotline service is available. Remote access for monitoring and supporting the system enables the localization and elimination of irregularities through teleservice. The Klinkhammer visualization tool, which is linked to the plant control system, increases plant safety and minimizes downtimes. Sensors provide data on the condition of machines and systems and can be analyzed in combination with error messages and statistics.

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