Storage and order picking technology
More efficiency and better conditions in the deep-freeze warehouse
Klinkhammer has implemented a fully automated, five-aisle deep-freeze warehouse for Früchte Jork, a family-run wholesale company for fresh food in the Allgäu region. In addition to increasing efficiency and picking performance, the client has also significantly improved the working conditions of its employees.
As one of the leading food wholesalers in the region, Früchte Jork supplies restaurants and hotels with a comprehensive range of food and non-food items. Due to growth and the expansion of the product range to around 13,000 items, the wholesaler had reached the limits of its capacity. In the previously manually managed deep-freeze warehouse, more than 1,000 different foodstuffs were picked manually with forklifts at -22 degrees Celsius. Based on future growth expectations, Klinkhammer worked with the owner family to plan a concept for a new deep-freeze warehouse. Storage capacity, functional and holding areas, throughput in order picking as well as organization and processes were analysed on the basis of the evaluated figures and optimized for the new warehouse logistics.
Automated TC warehouse relieves employees
The new five-aisle deep-freeze warehouse offers 26,280 shelf spaces and significantly speeds up logistics processes. The frozen products are retrieved fully automatically within a very short time, picked and delivered by a good 50 trucks in the fleet. Every day, around 600 customers within a radius of around 180 kilometers around Isny are served. Thanks to automation, fewer employees have to work in deep-freeze conditions. Ergonomically designed picking workstations make physical work easier and minimize bending and lifting heavy boxes.
With goods-to-person picking, the trays are delivered to the workstation at an ergonomic height using conveyor technology. It is important for picking staff that the goods are easy to grip. Compared to conventional containers, trays can be handled ergonomically. The low height facilitates gripping and enables efficient order picking. For Früchte Jork's customers, it is essential that the goods are available at the right time and in the right order for the right order. For this purpose, a sequence buffer has been provided at the picking stations to ensure that order sequences are adhered to. The source trays are temporarily stored in the sequence buffer and transported to the corresponding picking station after being called up.
Flexibility thanks to the trays as loading aids
By using trays as loading aids, cartons of various sizes, designs and heights can be stored flexibly in the automated small parts warehouse. The storage and retrieval machines (SRMs) are equipped with camera technology to visualize the telescopic areas and make it easier to control and monitor the system. Each SRM is equipped with power caps for energy recovery. Energy is not lost as heat when the stacker crane brakes, but is temporarily stored and made available again for the next acceleration process. The high storage density of the automatic storage system saves storage space, which in turn reduces the need for air conditioning and refrigeration technology. This enables reduced power consumption. Another decisive advantage of the automated warehouse is the precision, speed and route optimization in the goods storage and picking processes.
The opening of the automated deep-freeze warehouse is a milestone in the expansion of the Früchte Jork site in Isny. In a second construction phase, four automatic, high-performance shuttle warehouses are planned for the refrigerated and dry areas. They will cover different temperature zones. These shuttle warehouses also act as order consolidation buffers to automatically consolidate partial orders into one order. Maximilian Jork, who took over the management from his father Joachim Jork in 2020, confirms: "In recent years, we have evolved from a traditional fruit and vegetable wholesaler to a fresh produce service provider. The automated logistics center is another milestone in our growth strategy. With warehouse automation, we can manage our stocks more precisely, optimize energy consumption, maximize picking reliability and improve working conditions for our employees."
All food storage requirements taken into account
The Klinkware warehouse management system controls and monitors the material flows in the warehouse. The order in which the goods are delivered by the conveyor system during order picking is very important for foodstuffs. The software also takes into account aspects such as best-before date, batches and perishable goods. With the Klinkhammer visualization system Klinkvision, the system is displayed in dynamic overviews. All load carriers, whether on the conveyor system or in the high rack, can be clearly identified and localized at any time. The integrated sensors and drives in the transport control system help to provide rapid alarm diagnostics in the warehouse. All Klinkhammer systems are connected to the remote service and are monitored and supported centrally.
With the commissioning of the automated warehouse, Früchte Jork is ensuring energy-efficient storage with low space requirements, higher throughputs, shorter walking distances and overall improved working conditions for employees. With the new facility, Früchte Jork is setting an example for the future of food logistics.
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