The chemical and pharmaceutical company Merck Life Science from Darmstadt relies on BITO storage technology (flow racks & shelving units).

📈 Expansion of storage capacity 🚀

Merck Life Science KGaA, the Darmstadt-based chemical and pharmaceutical company with a history spanning over 350 years from a small pharmacy to a globally operating science and technology company, has comprehensively modernized its logistics operations. For the expansion of the storage and order picking area of ​​its distribution center, Merck selected flow racking and shelving systems from BITO-Lagertechnik Bittmann GmbH to implement a highly efficient racking system strategy.

The reorganization of the existing single-package warehouse, which spans ten rooms, incorporated state-of-the-art storage technologies. The entire conversion process was carefully planned and implemented in several phases to avoid interrupting operations.

Merck Life Science KGaA today stands not only for first-class pharmaceutical products, but also for pioneering research and development in the life sciences and the production of specialty chemicals for diverse applications. With over 12,000 employees, the company represents a significant workforce in Germany, operates in the healthcare, life science, and electronics segments, and manages its global operations from its headquarters in Darmstadt.

By investing in modern warehouse technology and strategically redesigning its logistics processes, Merck underlines its commitment to increasing efficiency, securing its innovative strength and maintaining its leading position in a highly competitive global market.

🔄 Focus on efficiency and ergonomics 📊

The company's key objective was to double its storage capacity within the existing space. This presented an immense challenge, as additional space had to be created without disrupting ongoing operations. Merck opted for a phased redesign, with each step carefully planned to avoid disrupting business.

🧪 Central importance for chemical logistics 💠

Merck's distribution center in Darmstadt serves as the hub for the logistics and distribution of the company's chemical products. Here, chemicals in various container sizes are efficiently stored and prepared for shipment. The decision to integrate BITO storage systems was a deliberate one. BITO solutions are known for their adaptability and ergonomics and were able to meet the specific requirements of a chemical company like Merck.

⚙️ Custom-made storage solutions for maximum space utilization 📏

BITO's custom-designed shelving systems and flow racks ensure space-saving storage of products up to a certain weight. This allows for more efficient use of available space and improved product accessibility. Furthermore, the ergonomic design of these racking systems has been given special consideration to minimize the physical strain on employees, particularly during the storage and retrieval of goods and order picking.

🏗️ Redesign of the individual packaging warehouse 🔄

The individual packaging storage area, the heart of the distribution center, has been completely redesigned to ensure efficient and safe storage of chemical products. BITO flow racks for individual items, equipped with plastic rollers, facilitate the transport of goods to the picking station – a significant improvement in workflows that has a positive impact not only on ergonomics but also on efficiency.

💧 Safety through intelligent design solutions 🔍

In accordance with stringent safety requirements, sprinkler systems were installed throughout the entire warehouse and order picking area. To complement this, the BITO shelving units are equipped with GRID mesh shelves, which guarantee optimal water and air permeability in the event of a fire. This functionality ensures that the sprinkler system operates efficiently in an emergency and minimizes potential damage.

🤝 Successful partnership and transformation 🤝

The conversion of the single-pack warehouse, consisting of ten different rooms, was successfully completed thanks to close collaboration with BITO warehouse technology. Restructuring the storage areas within the existing logistics building required close coordination between the planning teams from Merck and BITO, as well as a thorough analysis of the existing structures. In particular, varying ceiling heights and complex structural conditions had to be taken into account.

🚀 Future-oriented capacity expansion 🔮

This successful transformation demonstrates how innovative warehousing solutions and well-planned logistics can significantly increase the capacity of a distribution center – without requiring any changes to the building's size. The increased storage capacity now prepares Merck to accommodate an expanded product portfolio and efficiently meet market demand.

🌱 Sustainability and strategic corporate management 📈

Such modernization is not only proof of Merck's adaptability to changing market conditions, but also demonstrates the company's willingness to invest in the future viability of its operations. With regard to sustainability, more efficient use of space also contributes to reducing the company's environmental footprint. Optimizing warehousing plays a crucial role in Merck's corporate strategy and helps to consolidate and expand its position as one of the leading companies in the life science sector.

🌟 Resource allocation and continuous improvement ⭐

These redesigned warehousing and distribution processes exemplify the intelligent use of resources and the continuous improvement of operational procedures. They underscore Merck's commitment to being a leader in efficiency, safety, and innovation.

🌟 Details on the topic

• Merck has upgraded its distribution center in Darmstadt with BITO storage solutions.
• The renovation included the clever integration of BITO storage systems for improved ergonomics and standardized processes.
• The goal was to double the storage capacity within the existing space and to prepare for the intake of additional products.
• The new system takes into account different ceiling heights and complex structural elements within the building.
• BITO's solutions enabled ergonomic handling, increased efficiency, and optimized space.
• The phased transformation was carried out without disrupting daily operations, ensuring a smooth integration process.
• The partnership with BITO resulted in Merck's expectations being met at every stage, from planning to execution.

📣 Similar topics

• 🤩 Innovative warehouse solutions: The modernization of distribution centers in the chemical and pharmaceutical industry at Merck
• 🏗️ Efficiency increase: Merck's strategy to double storage capacity
• 🧪 Integrated warehouse solutions: The redesign of the distribution center at Merck in Darmstadt
• 📦 Space-saving measures: How Merck doubled its capacity through warehouse modernization
• 🔥 Safety and efficiency: The role of BITO storage systems in Merck's restructuring
• 🔄 Successful Transformation: How Merck Increased Its Storage Capacity Without Expanding Buildings
• 🍃 Sustainable warehouse optimization: Merck's contribution to reducing the ecological footprint
• 💼 Future-proof operational processes: Merck's willingness to invest in warehouse modernization
• 🚀 Changing market conditions: Merck's adaptability through increased warehouse efficiency
• 🏆 Exemplary warehouse processes: Merck's path to becoming a leader in efficiency, safety and innovation

#️⃣ Hashtags: #WarehouseModernization #EfficiencyImprovement #Innovation #Sustainability #Logistics

🛠️ The renovation of the warehouse and order picking area

The renovation of the warehouse and order picking area at Merck's distribution center was cleverly divided into seven phases. The replacement and modernization of the racking systems took place without interrupting daily operations, coordinated with all relevant trades. Felix Hensche explains: "Installation work by various trades sometimes took place in parallel with order picking activities in the same area. This was planned and implemented in such a way that regular operational processes could continue without interruption. The coordination between the renovation work, the installation team, and our operational activities was always excellent."

✨ Key factors for a smooth process

Key to the smooth project was the precise coordination of the delivery and assembly of the shelving units. "Even when spontaneous adjustments to the detailed schedule were necessary, BITO-Lagertechnik and the assembly team were always flexible and responsive. Urgently needed parts such as push-through protection, additional shelves, or extended impact protection were delivered immediately and integrated into the ongoing construction. The consistency of the assembly manager and team throughout the various construction phases was also a significant advantage. This greatly facilitated the uninterrupted progress of the conversion and installation work," said Hensche.

🚧 A special challenge

A particular challenge was that the assembly work was carried out in the highly sensitive area of ​​aviation security, which necessitated appropriate verification and special training of the assembly team.

📦 The perfectly coordinated BITO flow racks and shelf racks

The perfectly coordinated BITO flow racks and shelving systems are now an essential component of the logistics processes in the revamped single-pack area at the Merck Life Science KGaA distribution center. Furthermore, all internal processes and procedures have been optimally aligned with the new racking systems, increasing the company's efficiency and productivity. The new systems not only enable better space utilization but also contribute to improved workplace ergonomics, thus increasing employee satisfaction and safety. Thanks to state-of-the-art technology, the racking systems are flexibly adaptable and allow for scalable storage that can grow with Merck's requirements. This ensures future-oriented and sustainable growth for the company.

“With the equipment in the newly structured warehouse areas, every requirement we placed on BITO warehouse technology was implemented perfectly. From the tendering and award phase, through execution, and in the final result, our expectations were met to our complete satisfaction.” Felix Hensche, Project Manager Group Engineering Infrastructure & Logistics, Site Management | Engineering Services

At Merck's logistics center: Flow racks & shelving units – Image: BITO-Lagertechnik Bittmann GmbH

🏭 At the Merck logistics center

At Merck's logistics center, both BITO shelving units and flow racks now ensure efficient space utilization and ergonomic order picking. These systems allow for the safe and compact storage of individual bundles and outer packaging containing chemicals. Thanks to an intelligently designed layout, storage capacity has been significantly increased – the number of storage locations has more than doubled.

🔧 BITO shelving systems

BITO shelving systems are characterized by their adaptability in size and shape, making them an extremely flexible storage solution. Assembly is simple and can be modified to meet specific needs. Of particular interest to the chemical and pharmaceutical company Merck is the ability to integrate with existing sprinkler systems through the use of GRID mesh shelves, which offer water and air permeability for fire protection.

♻️ Flow racks for general cargo

Flow racks for individual items utilize both First-Expired-First-Out (FEFO) and First-In-First-Out (FIFO) principles, enabling optimized order picking. Moving goods automatically find their way to the picking side, significantly reducing the physical strain on employees and increasing the efficiency of the picking processes.

🚀 Contribution to productivity increase

These modern storage solutions make a significant contribution to increasing Merck's productivity by enabling fast and secure order picking. They also offer the potential for future expansion and can thus meet the changing requirements of a dynamic company like Merck.

Restructuring of the single-pack warehouse at Merck: Flow racks & shelving units – Image: BITO-Lagertechnik Bittmann GmbH

🎯📍 Targets and improvements

At its Darmstadt site, Merck has optimized the individual packaging warehouse within an existing logistics hall. The aim was to expand storage capacity, implement ergonomic improvements, and standardize processes. The redesigned storage and picking areas will now prepare finished products for shipment more efficiently.

🔍📦 Selection of the shelving system

When selecting the shelving system, Merck prioritized a space-saving solution that allows for ergonomic handling of packages up to 5 kg or liters. Previously, various types of shelving were used, which were replaced by a uniform system as part of the redesign to streamline processes.

📈⬆️ Doubling of storage capacity

The ambitious goal was to double the number of storage spaces in order to accommodate products from other locations in the same area and to prepare the warehouse for future product arrivals.

🔧📐 Flexible adjustment of the shelving system

The shelving system had to be flexibly adaptable to variable room heights and the existing infrastructure with concrete beams, sprinkler systems and conveyor technology.

🔄🛠 Phased implementation during ongoing operations

A critical aspect of the project was to carry out the conversion in stages while the facility remained operational – a particular logistical challenge.

🤝💼 Customer testimonial from Merck

Felix Hensche, Project Manager Group Engineering Infrastructure & Logistics at Merck Life Science KGaA: “BITO Storage Technology was already known to us as a reliable supplier from previous projects. Even in the initial inquiry phase of this project, the team demonstrated a high level of commitment in addressing our requirements and working with us to develop detailed solutions right from the start. We were then provided with sample racking systems that were perfectly suited to our application. During a factory tour at BITO in Meisenheim, we were also able to see for ourselves the quality of the products and the high level of vertical integration. The price-performance ratio was also the best – and so it quickly became clear that we would choose BITO in every respect.”

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