SCHWÄLBCHEN

Company

Since 1938, Schwälbchen is a recognised high-performance creamery running three sites – Mainz, Ilsfeld und Korntal-Münchingen. Whereas only 4 million kg of milk were processed annually in 1938, today's processing capacity has risen to almost 150 kg a year. The "green" product range "Grüne Linie" provides fresh milk and products that have to be kept cool such as cream and cheese. The company which employs 385 people is known for its regional products and for catering size packs for gastronomy.

Situation

  • The daily production of "green" products amounts to 500 - 600 pallets
  • Part of the pallets are stocked at the premises of an external service provider

    • As a result, access to stocks is time consuming and cost-intensive

  • Reacting to the strong growth in the past decades, a new cold store has been built to provide more storage capacity

Capabilities

  • Planned capacity of 1,300 European size pallets for cold store products
  • Product buffer for palletised goods
  • Optimum volume utilisation in view of cutting energy costs at a storage temperature of 5 °C

Solution

  • The mobile pallet racking facility BITO PROmobile accommodates 1,300 pallets on a small floor surface, thereby maximising volume utilisation

Customer benefits

  • „Compared to static racking with its broad service aisles, warehouse volume utilisation has now increased from 40 % to 75 % with this mobile facility
  • „„The BITO PROmobile pallet racking provides 75 % more storage capacity than the previously used static racking

WURZENER

Company

Wurzener is one of the most successful food producers in former East Germany. Their product range comprises 50 product lines for a healthy nutrition such as cereals, rice, pulse, convenience products, flour and snacks such as flips, potato chips, etc.

Situation

  • Each day, Wurzener has an output of 250 pallets of finished products which equals 3,000 truck loads a year
  • The products are stocked in bulk in the existing goods-out hall
  • There is an increasing demand for displayware in trade
  • As displays do not stack easily, the available storage volume for displayware is insufficient
  • Block storage causes damage to food packaging

Capabilities

  • Compact storage solution to be realised in the existing goods-out hall
  • Increase storage capacity
  • Damage-free storage of displayware

Solution

  • The BITO PROmotion shuttle facility accommodates 2,000 pallets
  • Channel storage facility with three levels makes best use of the warehouse volume
  • Efficient handling results in an improved goods-out process

Customer benefits

  • „Good space utilisation as better use is made of the warehouse height
  • „„No damage to displayware
  • „„Improved product handling as goods are in direct access

PILSNER URQUELL

Company

The name Pilsner Urquell alone is enough to inspire all beer lovers. Since the first Pilsner beer was brewed in October 1842, it has never lost its fascination. Today, the company with the time-honoured brewing tradition belongs to the second largest brewery in the world, the South Africa headquartered brewery group SAB, with an output of almost 240 million hectolitres in 2009.

On the Czech sites, approximately 2,400 employees are busy with producing, bottling and distributing 10 million hectolitres of beer a year. 800,000 hectolitres are exported from the distribution centre located at Plzen which is charged with the entire export organisation. The breweries deliver their output in lorries to this export warehouse where the deliveries are picked and packaged to order.

Situation

  • Storage, handling, packaging and shipment of entire pallet loads (glass bottles) and smaller packaging units (cans, nonreturnable bottles)
  • Storage is outsourced due to high space requirement
  • Transportation to the central export warehouse is expensive in times of high turnover
  • The risk of damage to cans and nonreturnable bottles is particularly high
  • Bad delivery quality and high costs for handling customer complaints

Capabilities

  • Increase throughput to 120 trucks a day, 40 of which are to deal with export deliveries
  • All off-premises depots are to be merged into one central export depot
  • Cut down transportation costs, increase product availability and product throughput, improve delivery quality, reduce customer claims
  • Production batches are to be on stock no longer than 30 days
  • Compensation of seasonal peaks

Solution

  • Compact storage in a pallet live installation providing 2,000 storage locations
  • The lane length has been calculated for up to 29 pallets handled according to the FIFO principle

Customer benefits

  • „Storage capacity has tripled from 700 to more than 2,000 pallets
  • „„Payback on investment within approximately 2 years
  • „Seasonal peaks can now be compensated easily, the product availability for delivery has been improved
  • „„The increased delivery quality has reduced the number of customer complaints

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