Honeycomb warehouse in the basement for aluminum profiles

A basement high-bay warehouse

For G. Baumgartner AG, Fehr is once again the first point of contact when it comes to the storage technology of a new production hall to be built. Since 2011, a Fehr Sidestacker and two Fehr Multi Towers for long goods have been fully automated in one of Europe’s most modern window production plants – at Baumgartner Fenster in Cham.

For the new production hall, Baumgartner Fenster, together with the specialists from Fehr, is developing an in depth concept: in order to create as much space for production as possible on the ground floor of the hall, it is decided to build the high-bay warehouse and parts of the production underground.

The high-bay warehouse in the basement is not only fascinating with the dimensions of eleven meters high, 23 meters wide and 45 meters long. The Fehr Honeycomb warehouse also impresses with its 1,215 parking spaces and 1,500 kilograms of payload per cassette for the aluminum profiles that are constantly needed in production.

A double-table shelf control unit Fehr RBG1 light operates the warehouse fully automatically. The facility also consists of three carousels with two with four storage units and one with six storage units. Four longitudinal conveyors, three weighing devices and a commissioning tower together with a telescope and excavating device make the system complete for operation. As a full-service supplier, Fehr also supplied the electrical control, the safety device and with Fehr WMS also the appropriate warehouse management system.

Fehr was able to save additional space for the client and significantly shorten the working distances by customizing the safety device. If an employee is close to the warehouse, the system automatically reduces the speed for security reasons. As soon as the employee moves away and additionally actuates a safety switch, the storage system picks up its full speed.

However, the honeycomb warehouse is only part of the sophisticated storage solution for the window profiles. In order to bring the delivered material into the basement for storage as space-saving and efficient as possible, a tower warehouse also operates in the basement.

A freestanding Fehr Multi Tower is directly connected to the honeycomb warehouse. It rises up to the ground floor and is stocked here with the incoming deliveries directly from the trucks. The tower warehouse serves as a lift and as an intermediate buffer for the incoming deliveries. As soon as the honeycomb warehouse rack control unit finds time between the prioritized orders from the production, it begins to transfer the delivery from the cassettes of the Fehr Multi Tower into the Fehr Honeycomb. Through the upstream ERP system, the Fehr WMS warehouse management system also knows at any time when the next truck deliveries are to be expected.

The entire system was planned, delivered and assembled by Fehr from a single source. Like most customers, Baumgartner Fenster commissioned the Fehr specialists with the process analysis, planning, delivery, assembly, project management and commissioning, as well as the programming of the Fehr WMS.