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

📈 Expansion of storage capacity 🚀

The Darmstadt-based chemical and pharmaceutical group Merck Life Science KGaA, which has a history spanning over 350 years from a small pharmacy to a global science and technology company, has comprehensively modernized its logistics area. To expand the storage and picking area of ​​its distribution center, Merck chose flow and shelving racks from BITO-Lagertechnik Bittmann GmbH to implement a highly efficient racking system strategy.

The most modern storage technologies were incorporated into the reorganization of the existing single-pack warehouse, which extends over ten rooms. The entire renovation process was carefully planned and implemented in several phases so as not to interrupt operations.

Today, Merck Life Science KGaA not only stands for first-class pharmaceutical products, but also for groundbreaking research and development in the life sciences and the production of specialty chemicals for various areas of application. In Germany, the company represents a significant workforce with over 12,000 employees, is active in the Healthcare, Life Science and Electronics segments and runs its global operations from its headquarters in Darmstadt.

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

🔄 Efficiency and ergonomics in focus 📊

The company's key goal was to double the storage capacity within the existing space. This presented an immense challenge as additional space had to be created without impacting ongoing operations. Merck decided to undertake a gradual transformation, with each step carefully planned so as not to disrupt operations.

🧪 Central importance for chemical logistics 💠

Merck's distribution center in Darmstadt acts as the heart of the logistics and distribution of the company's chemical products. Chemicals in various container sizes are efficiently stored here and prepared for shipping. The decision to integrate BITO storage systems was no coincidence. BITO solutions are known for their adaptability and ergonomics and were able to meet the specific needs of a chemical company like Merck.

⚙️ Custom-made storage solutions for maximum space utilization 📏

The tailor-made BITO shelving units and the general cargo flow racks ensure space-saving storage of products up to a certain weight. This allows for more efficient use of the available space and better accessibility of products. In addition, the ergonomic design of these shelving systems was given special consideration in order to minimize the physical strain on employees. This applies in particular to the storage and retrieval of goods as well as picking.

🏗️ Redesign of the single pack warehouse 🔄

The single pack storage area, the heart of the distribution center, has been completely redesigned to ensure effective and safe storage of chemical products. The BITO general cargo flow racks, equipped with plastic rollers, make it easier to transport goods to the picking point - a significant improvement in work processes that not only has a positive effect on ergonomics, but also on efficiency.

💧 Safety through intelligent design solutions 🔍

In accordance with strict safety requirements, sprinkler systems have been installed throughout the storage and picking area. To match this, the BITO shelving units are equipped with GRID grid shelves, which guarantee optimal water and air permeability in the event of a fire. This functionality ensures that in the event of an emergency, the sprinkler system functions efficiently and potential damage is minimized.

🤝 Successful partnership and transformation 🤝

The conversion of the single-pack warehouse, consisting of ten different rooms, was carried out without any problems thanks to the close cooperation with BITO-Lagertechnik. The restructuring of the storage areas in the middle of the existing logistics building required close coordination between the Merck and BITO planning teams and a precise analysis of the existing structures. In particular, different ceiling heights and complicated structural conditions had to be taken into account.

🚀 Future-oriented expansion of capacities 🔮

This successful transformation shows how innovative storage solutions and well-thought-out logistics can significantly increase the capacity of a distribution center - without the need to change the size of the building. The increased storage capacity now prepares Merck to accommodate an expanded product portfolio and efficiently serve market demand.

🌱 Sustainability and strategic corporate management 📈

Such modernization not only demonstrates Merck's ability to adapt to changing market conditions, but it also demonstrates the company's willingness to invest in the future viability of its operations. With a view to sustainability, the more efficient use of space also helps to reduce the company's ecological footprint. Optimizing warehousing plays a crucial role in Merck's corporate strategy and helps consolidate and expand its position as one of the leading companies in the life sciences sector.

🌟 Use of resources and continuous improvement ⭐

These redesigned warehouse and distribution processes exemplify the intelligent use of resources and the continuous improvement of operational processes. They underscore Merck's commitment to being a pioneer 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 better ergonomics and standardized processes.
• The goal was to double storage capacity within the existing space and prepare to accommodate 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 optimization of space.
• The phased transformation was carried out without impacting 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 storage solutions: The modernization of distribution centers in the chemical-pharmaceutical industry at Merck
• 🏗️ Increased efficiency: Merck's strategy to double storage capacity
• 🧪 Integrated storage 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 its building
• 🍃 Sustainable warehouse optimization: Merck's contribution to reducing the ecological footprint
• 💼 Sustainable operations: Merck's willingness to invest in warehouse modernization
• 🚀 Changing market conditions: Merck's adaptability through increasing efficiency in the warehouse
• 🏆 Exemplary warehouse processes: Merck's path to becoming a pioneer in efficiency, safety and innovation

#️⃣ Hashtags: #warehouse modernization #increasing efficiency #innovation #sustainability #logistics

🛠️ The renovation of the storage and picking area

The conversion of the storage and picking area in Merck's distribution center was cleverly divided into seven phases. The change and modernization of the shelving systems took place without interrupting daily business, coordinated with all the associated trades. Felix Hensche explains: “Assembly work by various trades sometimes took place parallel to the picking activities in the same area. This was planned and implemented in such a way that regular operating processes could continue without restrictions. The coordination between the renovation work, the assembly team and our operational activities was always excellent.”

✨ On the success factors for a trouble-free process

One of the success factors for the trouble-free process was the precise timing of the delivery and assembly of the shelf elements. “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 collision protection were delivered immediately and integrated into the ongoing construction. A significant advantage was also the consistency in the deployment of the assembly manager and the team across the various construction phases. This significantly promoted the undisturbed progress of the conversion and installation work,” says Hensche.

🚧 A special challenge

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

📦 The perfectly coordinated BITO general cargo flow and shelf racks

The perfectly coordinated BITO general cargo flow and shelf racks are now an essential component of the logistical processes in the revised area for individual packs in the Merck Life Science KGaA distribution center. In addition, all internal processes and procedures have been optimally coordinated with the new shelving systems, which increases the company's efficiency and productivity. The new systems not only enable better use of space, but also contribute to improved ergonomics in the workplace, which increases employee satisfaction and safety. Thanks to state-of-the-art technology, the shelving systems are flexibly adaptable and allow 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 storage areas, each of the requirements we placed on BITO storage technology was implemented 1:1. Our expectations were met to our complete satisfaction right from the tender and award phase, and later during the execution and the result.” Felix Hensche, Project Manager Group Engineering Infrastructure & Logistics, Site Management | Engineering Services

In the Merck logistics center: flow racks & shelving racks – Image: BITO-Lagertechnik Bittmann GmbH

🏭 In the Merck logistics center

In Merck's logistics center, both BITO shelving racks and flow racks now ensure efficient use of space and ergonomic picking methods. These allow individual containers and outer packaging containing chemical ingredients to be stored safely and compactly. An intelligently designed arrangement made it possible to significantly increase storage capacity - the number of storage spaces more than doubled as a result.

🔧 BITO shelving systems

BITO shelving systems are characterized by their adaptability in size and shape, making them an extremely flexible storage solution. Installation is simple and can be modified as needed. Particularly interesting for the chemical and pharmaceutical company Merck: The adaptation to existing sprinkler systems through the use of GRID grid shelves, which offer water and air permeability for fire protection.

♻️ General cargo flow racks

General cargo flow racks use a first-expired-first-out (FEFO) and a first-in-first-out (FIFO) principle, which enable optimized picking. Goods stored in a mobile manner automatically find their way to the picking side, which significantly reduces the physical strain on employees and increases the efficiency of the picking processes.

🚀 Contribution to increasing productivity

These modern storage solutions make an enormous contribution to increasing Merck's productivity by enabling quick and safe order picking. They also offer the potential for future expansion and can therefore meet the changing requirements of a dynamic company like Merck.

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

🎯📍 Targets and improvements

In the company complex in Darmstadt, Merck has optimized the single-pack warehouse within an existing logistics hall. The aim was to expand storage capacity, make ergonomic improvements and standardize processes. The redesigned storage and picking areas will now be able to prepare finished products for shipping more efficiently.

🔍📦 Selection of the shelving system

When selecting the shelving system, Merck placed emphasis on a space-saving solution that enables ergonomic handling for packages weighing up to 5 kg or liters. Previously, various types of shelves were used, which were replaced by a uniform system as part of the redesign in order to standardize the processes.

📈⬆️ Doubling storage capacity

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

🔧📐 Flexible adjustment of the shelving system

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

🔄🛠 Gradual implementation during ongoing operations

A critical aspect of the project was to carry out the conversion in stages during ongoing operations - a particular logistical challenge.

🤝💼 Customer testimonial from Merck

Felix Hensche, Project Manager Group Engineering Infrastructure & Logistics at Merck Life Science KGaA: “BITO-Lagertechnik was already known to us as a reliable supplier from previous projects. In this project, too, it became clear in the inquiry phase how committed the team was to dealing with the requirements in order to work with us to develop detailed solutions right from the start. We were then provided with sample shelves that exactly matched our application. During a factory tour at BITO in Meisenheim, we were also able to convince ourselves of the quality of the products and the high level of vertical integration. The mix of price and performance was also the best – and so it quickly became clear that we would choose BITO in all respects.”

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