Mayr-Melnhof Holz Holding, headquartered in Leoben, was founded in 1850 and is one of Europe's leading companies in the sawn timber and wood processing sectors. Around 1,630 people are employed at nine locations. A modern intralogistics solution has been created at the sawmill site in Leoben, which is also home to the company headquarters, with an automated, three-aisle high-bay warehouse as well as the connecting conveyor technology for order-related sequencing, packaging, stacking and tour-specific provision with subsequent truck loading in the loading hall, which is also semi-automated for the first time. Based on the functional specifications of the logistics planner Xvise from Lauterbach (Austria), Hörmann Intralogistics developed a convincing concept for Mayr-Melnhof Holz and was awarded the general contractor contract for the realization of this special intralogistics solution.

Stephan Dorn, Project Manager Realization at Hörmann Intralogistics, comments: "This project was an exciting challenge that we accepted with enthusiasm, but also with a great deal of respect. The close cooperation with Mayr-Melnhof Holz enabled us to develop a tailor-made solution that is both efficient and forward-looking. We are proud of the result and the sustainable improvements it brings for our customer."

The concept

The high-bay warehouse (HRL) as well as the logistics and loading hall were built on an existing site next to the existing production halls of the sawmill and directly adjacent to the newly constructed high-performance post-sorting and planing mill and the new high-tech cross-laminated timber plant. The conveyor system transports the timber packages from the sorting and planing mill to the high-bay warehouse. In the three-aisle high-bay warehouse, the timber packages are temporarily stored and, depending on the order, either loaded onto trucks for internal and external customers or transferred to the cross laminated timber plant for further processing. For truck loading, the sawn timber packages are put together in the correct sequence and route, packed and stacked if required. A distribution truck then transports the heavy-duty packages to the respective staging lane next to trailers in the loading hall.

Stefan Hierzenberger, Head of Group Logistics at Mayr-Melnhof Holz, adds: "The all-in-one concept from Hörmann Intralogistics has enabled us to revolutionize our logistics processes. The designed software control, sensor technology, innovative conveyor technology and seamless integration into our existing processes increase our efficiency and competitiveness. We are enthusiastic about the possibilities offered by this new system."

Flexible and gentle material flow

The load units are bundled packages of sawn timber measuring up to 5.2 m long, 1.27 m wide and 1.30 m high and weighing up to 3,200 kg. To transport the packages safely and gently on the conveyor system, Hörmann Intralogistics uses an innovative modular belt conveyor system made of high-quality, lubricant-free plastic with integrated transport rollers. The packages can be transported on these with or without squared timber. On transfer from the sorting and planing mill, all packages undergo a weight and contour check. Coming from the sorting and planing mill, the timber packages are automatically picked up, checked and transported to the pre-zone of the high-bay warehouse. At the storage infeed, packages up to 4.2 m and 2.7 t are positioned centrally to the storage and retrieval machine (SRM) according to their lengths and transferred by the SRM to triple-deep rack storage locations.

Order-related sequencing and gantry robot station

The timber packs are then removed from storage in the correct sequence and to the exact route. During this process step, there are further sorting options directly on the conveyor system. For the most part, the packages are wrapped fully automatically at the customer's request, placed underneath with squared timber by a robot and strapped. After automatic labeling, the parcels are stacked.
This takes place in the hall's pre-zone, where up to four parcels can be put together by a portal stacker to form a lift for truck loading. Two parcels next to each other and two parcels on top of each other form this lift. In the post-storage zone of the high-bay warehouse, retrieval slots have also been included in each rack aisle. Here, packages of sawn timber are retrieved and fed to the cross laminated timber plant via a distribution trolley.

Intelligent intralogistics strategies realized

Warehouse management, system control and system visualization are carried out with the Hörmann Intralogistics Warehouse Management System HiLIS, which communicates with the customer system via an interface. With 24/7 operating times, HiLIS continuously receives retrieval and storage orders for the items to be loaded via an interface from the on-site host.