Retrofit in the high-bay warehouse: Targeted innovations pay off – high-bay systems with stacker cranes and pallet conveyor technology

A solidly constructed high-bay warehouse can meet the operator's performance requirements with virtually no restrictions, even after 20 years of intensive use. Assuming regular maintenance and servicing of all components, the service life of storage and retrieval machines or pallet conveyor technology can be extended far beyond this through a targeted retrofit. With the support of LogBer, costly new investments can be avoided in a comparatively simple way.

💼 Success story: Longevity through retrofit

“Renewing outdated system components and modernizing outdated control and drive technology is still economical and sensible for a high-bay warehouse, even after an operating period of more than 30 years,” says Gerhard Keller, Managing Director of LogBer GmbH. “As a rule, such an investment is depreciated over 15 to 20 years, but in practice even high-bay warehouses with 24/7 operating times and high performance requirements often function well beyond this period.” Gerhard Keller cites a system built in 1980 as an example was subjected to a targeted retrofit 15 years ago according to a concept developed by LogBer and is still in use unchanged after more than four decades.

📊 Logistics planner with relevant experience

However, in order for retrofitting in high-bay warehouses to be successful, extensive preparatory work and experienced logistics planners who know how to deal with the imponderables of such a project are required. In this specific case, LogBer accompanied the renewal of the entire control technology of both the storage and retrieval machines and the pallet conveyor technology. All drives of the storage and retrieval machines were replaced with energy-efficient and easy-starting drives. Rails that were worn on one side had to be sanded down and a stacker crane that had been damaged by the high dynamic forces had to be completely replaced because significant weld cracks had formed in the carriage and mast.

🛠️ Challenges and solutions

Before that, there were still a few hurdles to overcome, reports LogBer managing director Gerhard Keller: “The manufacturer and installer of the high-bay system no longer existed. Nevertheless, we found three companies in the logistics market that specialize in retrofitting third-party systems for an initial inspection and assessment of the possible costs.” Finally, the systems were modernized aisle by aisle while operations were ongoing: controls (PLC, sensors, etc.) were updated to the state of the art brought, the drive technology was replaced by more energy-efficient and easy-to-start systems, the travel and guide rails were readjusted, the travel rails were ground, the running wheels were replaced and, finally, the warehouse management and material flow control were adapted to contemporary logistical requirements.

📝 Careful planning and step-by-step approach

Nevertheless, Gerhard Keller states: “The preparation, planning and implementation of a retrofit/reengineering project is very time-consuming overall, and the necessary measures are difficult to calculate in advance.” In order to be able to estimate the effort as precisely as possible, LogBer breaks down the procedure four phases: The analysis of the current situation and the operational requirements is followed by the development of the retrofit concept, then the detailed planning and tendering of the necessary work continues, and finally implementation, testing and commissioning follow.

💰 Is it worth the effort?

“All in all, the effort is quite large, but it is definitely worth it,” summarizes Gerhard Keller. The retrofit of the facility built in 1980, realized with the support of LogBer, ultimately made the construction of a new high-bay warehouse unnecessary - and reduced the costs to just 20 percent of the new investments that would otherwise be required.

In today's world, when sustainability and resource conservation are becoming increasingly important, the history of retrofitting in high-bay warehouses shows how existing systems can be used reliably and efficiently for many years to come through clever modernization and maintenance. It is an example of how technical innovation and logistics planning go hand in hand to increase the efficiency of operations while reducing environmental impact.

💼 LogBer GmbH

LogBer GmbH has been planning solutions and optimizing processes for efficient logistics for more than 25 years. As an independent partner, planner and project manager, LogBer accompanies projects holistically, from analysis and planning to tendering and implementation - in all industries from manual to fully automated warehouses to entire locations.

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Logistics sustainability is playing an increasingly important role in the business world today. Companies are increasingly realizing that they not only have to pay attention to economic efficiency, but also to ecological and social responsibility. An important component in this context is the optimization of high-bay warehouses, as these can have a significant impact on a company's environmental balance and operating costs.

High-bay warehouses are widely used in many industries and are used to store large quantities of goods in a small space. They are often highly automated and offer many advantages, such as better use of space and faster picking of products. However, there are some important aspects that should be taken into account when optimizing these warehouses to improve their logistical sustainability.

1. 🌍 Energy efficiency and resource utilization

The energy efficiency of a high-bay warehouse is crucial to its sustainability. It is important to ensure that lighting, climate control and warehouse automation systems are operating as efficiently as possible. This can be achieved through the use of LED lighting, intelligent control technology and regular maintenance.

In addition, resource utilization should be optimized. This includes minimizing packaging materials and eliminating waste when storing and transporting goods. A smart shelving system can help reduce space requirements and make storing products more efficient.

2. ♻️ Sustainable materials and construction

When planning and building a high-bay warehouse, preference should be given to sustainable materials and construction methods. This can include the use of recycled building materials, energy-efficient insulation materials and environmentally friendly roof and facade systems. A well-insulated warehouse can reduce energy consumption for air conditioning and keep the temperature in storage areas stable.

3. 🤖 Automation and robotics

Automation technology and robotics play an important role in optimizing high-bay warehouses. Robots can work more efficiently than humans and can help speed up the storage and transportation of products. This can not only reduce operating costs, but also reduce energy consumption since robots require less energy than human workers.

However, it is important to ensure that the robots and automation systems used are energy efficient and easy to maintain. This can be achieved through the use of intelligent control systems and regular training for operating personnel.

4. 🌐 Sustainable sourcing and supply chain

Logistics sustainability does not end with the warehouse, but extends to the entire supply chain. Companies should strive to develop sustainable sourcing practices and select suppliers that use environmentally friendly materials and processes. This can help reduce the environmental footprint of the entire supply chain.

In addition, supply chain logistics planning should be designed in such a way that transport routes are optimized and emissions are minimized. This can be achieved, for example, by using environmentally friendly means of transport and bundling deliveries.

5. 📊 Data analysis and optimization

Continuous analysis of data is crucial for optimizing a high-bay warehouse. Modern technologies such as the Internet of Things (IoT) make it possible to collect and analyze a variety of data from the warehouse. This can help identify and resolve bottlenecks and inefficient processes.

By using data, inventory levels can be optimized, product picking can be improved, and storage capacity can be maximized. This not only results in better operational efficiency, but also a reduction in energy consumption and environmental impact.

6. 👩‍🔧 Employee engagement and training

Employees play an important role in ensuring the logistical sustainability of a high-bay warehouse. It is important to sensitize and train them on sustainable practices. This can help ensure they adopt energy efficient behaviors and minimize waste.

In addition, employees should be included in the optimization process. They can provide valuable insights and ideas for improving warehouse processes and reducing environmental impact.

🏢📦 Optimization of high-bay warehouses

Optimizing high-bay warehouses for logistical sustainability is a complex task that includes various aspects of warehousing and supply chain. Companies that choose sustainable practices can not only reduce their environmental impact, but also reduce long-term costs and strengthen their image as an environmentally conscious company.

The above measures, such as improving energy efficiency, using sustainable materials and technologies, automation and robotics, supply chain optimization, data analysis and employee engagement, are crucial to success in this area. Companies should be aware that logistics sustainability is not only a commitment to the environment, but can also provide economic benefits.

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#️⃣ Hashtags: #sustainability #logistics #high-bay warehouse #environmental protection #efficiency

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