Digitalization, a shortage of skilled workers, rising cost pressures and ever shorter delivery times pose major challenges for metal-working companies. Many existing storage facilities, which still rely heavily on manual processes and outdated controls, can no longer meet these requirements. With a targeted retrofit from Fehr, we bring your existing plant up to date economically, increase performance and efficiency – and at the same time avoid the risks and high costs of a new building.
Retrofit solutions for long and flat goods storage
The basic structure of stores for long and flat goods – steel structures, cassette stores, honeycomb racks and conveyor systems – is often designed for decades of use. The "nervous system" of the system, consisting of control, drives and bearing management software, on the other hand, quickly reaches its limits.
With a retrofit, we modernize these components, optimize software and processes, increase reliability, reduce downtime and extend the service life of the entire plant often by 20 years or more.
Retrofit vs. new construction – saving costs and increasing safety
Retrofitting saves considerable costs: Existing steel scaffolding and foundations can continue to be used, and expensive civil engineering or steel construction work is eliminated. Retrofit projects are generally only 30 to 50 percent of the cost of a new building. At the same time, modern safety standards are being implemented, which can also reduce insurance premiums.
Automated processes increase efficiency and relieve staff
Automated processes reduce physically stressful activities and enable more efficient use of personnel. Modern warehouse management software optimizes the travel paths of the shelf operating devices, minimizes empty runs and efficiently controls material flows. Material can be transferred directly from the warehouse to saws, laser or CNC centers.
Optimized cartridge guides and modernized load-bearing equipment also increase the storage capacity. With suitable hall height and statics, additional storage levels or rows of shelves can be integrated, which are operated by the existing system.
Conversion to retrofit with minimal production stoppages
Cessation of production is expensive. Retrofit measures can be implemented step by step: control upgrades, mechanics, peripherals or ERP connections can be installed independently of one another, usually during planned production breaks. Even extensive conversions can be realized so quickly, with minimal downtime.
Energy efficiency and cost reduction through retrofit
Through modernized technology and optimized processes, we significantly reduce energy consumption and operating costs. Efficient drives, optimized driving logic and feedback of energy surpluses make retrofits not only powerful, but also sustainable.
Holistic retrofit solutions – also for systems from other manufacturers
In order for a retrofit to reach its full potential, we consider all aspects of the warehouse and the connected processes holistically. Existing hall structures, shelf systems, conveyor technology, machines from different manufacturers and digital interfaces are seamlessly integrated. We also modernize and automate systems from other manufacturers so that material flow, control and peripherals work together optimally.
From initial analysis through planning, project planning and implementation to acceptance, we accompany our customers as an experienced contact person – for minimum downtime, maximum efficiency and a smooth transition to productive operation.
In a retrofit, many technical and organizational steps need to be precisely aligned to ensure time frames are met and downtime minimized. It is therefore crucial for our customers to have an experienced contact person at their side from the initial contact to acceptance who will accompany them through every step of the process.
Gerd Jakob, project manager
Retrofit Example: Fully automated in three weeks
At stürmsfs AG, we have completely modernized an existing long goods warehouse within just three weeks. The shelf operating device, control and periphery have been updated, and the loading of the saw lines has been automated. The system processes rods with diameters from 12 to 110 mm and weights up to 450 kg, makes optimum use of 3,800 storage locations and enables a continuous, automated 24/7 loading with consistently high product quality. Thanks to precise planning, production was able to continue almost uninterrupted.
The fact that we were able to modernize the entire system in just three weeks over the Christmas holidays and thus maintain the current operation almost continuously is an impressive success for us
Domingo Messerli, Managing Director at stürmsfs AG
