The special feature of the four-aisle channel storage system is the multi-deep transverse storage of different finished goods formats on different pallet types and on several sub-pallets. Kunert Wellpappe Bad Neustadt GmbH & Co KG is part of the family-run Kunert Group. Today, the Kunert Group employs 1,900 people in 16 plants in Europe and Asia. Every year, the Kunert Group produces 300,000 tons of cores, edge protectors and packaging made of corrugated board as well as over 225,000 tons of core board.

The concept
The packing units are transported from production on a distribution trolley to the new conveyor system. As early as the production stage, care is taken to ensure that two identical packing units are always transported one behind the other, which can then be conveyed as pairs in the high-bay warehouse area and stored and retrieved. This significantly increases the throughput of the warehouse. A packing unit can have up to six sub-pallets. The packing units are centered and checked for length, width, height, pallet width, pallet length and weight via a contour check. The conveyor technology then transports the packing units to the pre-zone of the high-bay warehouse, where a pallet circuit with special chain conveyors and roller lifting tables connects the production, high-bay warehouse and dispatch preparation areas.

For storage in the new channel storage system, the packing units are precisely positioned at the storage point with the aid of a light grid. The two-mast storage and retrieval machines (SRMs) are equipped with chain conveyors and channel vehicles. In two aisles of the warehouse, the SRMs work with one channel vehicle each, in the other two aisles with two channel vehicles each to handle the transportation of large pallets. The channel vehicles are battery-operated and are charged at the stacker crane during operation. The storage and retrieval machine picks up the packing unit crosswise and stores it multiple-deep in the storage lanes with the help of the channel vehicles. During order-related retrieval, the HiLIS warehouse management and control system receives a retrieval order via an interface from the on-site HOST. The goods are retrieved by the storage and retrieval machines and transported to the dispatch area via conveyor technology. There are different loading areas for truck rear loading and truck side loading.

Different formats as a difficulty
The particular challenge in the detailed planning and implementation of the new channel storage system at Kunert Wellpappe lies in the very different formats and the large-format packaging units with several sub-pallets. In addition to transporting these very different packaging units on a special conveyor system, a compartment detail was required that would allow the large compartments to be used flexibly and with optimum volume. The height of the high-bay warehouse of around 42 meters is also unusual. This height is the result of the limited space available on the factory premises and the need to accommodate the maximum number of pallet spaces on the available area.

Hörmann Logistik's scope of supply includes rack steel construction, roof and wall cladding including SHEVS, drainage and lightning protection, pallet conveyor technology for the transfer of packing units from production as well as the connection of the high-bay warehouse, block storage and dispatch, storage and retrieval machines, fire protection doors and high-speed doors, rack sprinklers, warehouse management and control system HiLIS including system visualization.