German industry in the rush of height: Highly bay warehouse transforms logistics sustainable and digital

Digitization and sustainability: The rise of the high -bay warehouse

Forget dusty warehouses and inefficient logistics - a silent revolution has taken place in German industry! High -bay warehouse is no longer just a niche topic for specialized industries. From the supermarket giant to car manufacturers, from chemical group to medium -sized companies - more and more companies are relying on the vertical power of the high -bay warehouse to raise their logistics processes to a new level.

This trend goes far beyond pure capacity expansion. Automation and digitization are the drive springs of this development. Robot -controlled systems, intelligent software and a strong focus on sustainability make high -bay warehouses into key components of modern, efficient and future -proof supply chains.

In this article, discover how industry sizes such as Kaufland, Porsche and Beiersdorf invest in impressive high -bay warehouse and what groundbreaking advantages this technology offers for companies of all size. Learn how spatial optimization, cost reduction and sustainability go hand in hand and why high -bay warehouses will significantly shape the future of industrial logistics in Germany. Immerse yourself in the fascinating world of vertical storage and be inspired by the innovative solutions and impressive examples!

Highly bay warehouse: The vertical revolution in German industry

In the complex world of modern industry, in which speed, efficiency and precision decide on competitiveness, a technology has established itself as an indispensable pillar: the high -bay warehouse. What once started as a special solution for a few industries is today a cross -industry phenomenon and a key module in the logistics strategies of numerous companies in Germany. A profound analysis of current developments shows that German companies from a wide variety of sectors massively invest in fully automated high -bay warehouse. These investments are not a coincidence, but a strategic answer to the growing requirements of the market, the increasing competitive pressure and the need to be prepared for future challenges.

Particularly noteworthy is a triple trend: automation, digitization and growing awareness of sustainability. Modern high -bay warehouses are no longer just pure deposits; They are highly complex, digitally networked systems that are seamlessly integrated into overarching production and logistics processes. At the same time, the aspect of energy efficiency and environmental compatibility is becoming increasingly important, since companies strive to minimize their ecological footprints and protect resources.

The following explanations offer a comprehensive insight into the fascinating world of high -bay warehouse and shed light on their diverse use in the most varied of branches of industry in Germany. We will investigate how this technology optimizes logistics processes, what technical features you distinguish and what economic advantages you offer companies. In addition, we take a look at the future trends and development prospects that will further expand the potential of high-bay warehouse technology.

Suitable for:

• From buffer storage for fresh logistics and refrigerated logistics warehouses to automated AI high-bay warehouses and pallet warehouses

Cross -sector distribution: from the supermarket to the automobile plant

The spread of high -bay bearings in Germany is impressive and extends over almost all producing industry. What once started in a few, specialized industries has developed into a nationwide trend. The continuous technological development, the falling costs and the increasing knowledge of the economic and ecological advantages of these systems have meant that high -bay warehouses are entering more and more industries. There is no exaggeration to say that you have developed from a niche solution to an industrial standard.

Food industry and trade: freshness and efficiency in focus

In the food industry and in retail, high -bay warehouse has long since become an integral part of modern logistics centers. Especially in this sector, in which freshness, speed and the highest hygiene standards are decisive, high -bay warehouses play their strengths fully.

Kaufland, a giant in German retail, recognized this and completed a comprehensive transformation of its logistics center at the Geisenfeld location. A large part of the company has been fully automated since September 2024. The heart of this modernization is a newly committed high -bay warehouse, which enables a significant capacity expansion without additional space consumption. This is an enormous advantage in densely populated areas and expensive commercial areas. The increased storage capacity contributes directly to delivery security, since larger quantities of goods can be stored in order to better cushion demand fluctuations and delivery bottlenecks.

In the daily operation of the Kaufland logistics center, impressive quantities are moved: up to 185,000 colli are picked fully automatically, with shelf control units precisely and efficiently stored and outsourced. A special highlight is the automated picking system for fruit and vegetables that can master up to 50,000 colli every day. This special system is an example of the high flexibility of modern high -bay warehouse, which can be adapted to the specific requirements of various product groups. Automation in this area not only reduces personnel expenses, but also minimizes the risk of damage and spoilage of the sensitive goods.

The family company Seeberger, known for its high -quality natural snacks such as nuts, dried fruit and coffee, also relies on high -bay warehouse. At the Ulm location, Seeberger is investing in an additional, impressive high -bay warehouse. With a length of 90 meters, a width of 21 meters and a height of 45 meters, this warehouse will offer around 20,000 pallet parking spaces and is expected to go into operation in spring 2026. The consistent orientation towards sustainability is particularly noteworthy here. A new facade cladding should ensure a stable temperature spectrum inside the warehouse, both in summer and in winter, without active cooling. This passive air conditioning is an important step to reduce energy consumption and operating costs.

The Alpenhain dairy in Upper Bavaria has also invested in a new high -bay warehouse to optimize its logistics processes and reduce the costs of warehousing. The 80x20x22 meter camp is designed as a frozen bearing and enables flexible response to demand fluctuations in chilled and frozen products. In the food industry, especially for dairy products, compliance with the cold chain is of the utmost importance. A frozen store in a high -shelf construction offers ideal conditions here, since it enables precise temperature control and efficient use of space. The flexible interpretation as a frozen warehouse allows Alpenhain, depending on the market situation and demand, to adapt the ratio of cooled to frozen storage spaces.

A similar development can be observed in Hochland, another important dairy company. At the Schongau location, a high -bay warehouse with around 10,000 pallet spaces was built on nine levels and a height of around 25 meters. This warehouse serves the efficient storage of cheese and other dairy products and helps to secure the high quality standards and the fast delivery capacity of highlands.

Automotive industry: precision and just-in-time for complex production

The automotive industry, traditionally a pioneer in innovation and efficiency, intensively uses high-bay warehouse to optimize their complex production and logistics processes. In this industry, in which just-in-time deliveries and high-precision manufacturing processes are decisive, high-bay warehouse plays a key role.

Porsche, an icon of German automotive construction, is massively investing in the conversion and expansion measures of sports car manufacturing and logistics at its main plant in Stuttgart-Zuffenhausen in order to be equipped for the future. The core elements of these investments are a so -called “flexiline” for two -door sports cars and two new high -bay warehouse. The “Flexiline” stands for a flexible and state -of -the -art production line that can quickly adapt to changed production requirements. After the planned completion in 2025, the new high-bay warehouse will supply the body car of the Taycan and sports car production with vehicle parts via two floors. This direct connection to production is a typical feature for the use of high -bay bearings in the automotive industry, where camps often serve as a buffer between production and assembly.

BMW has built an architecturally impressive high -bay warehouse for body in its Munich main plant. With a height of 41 meters, it is the highest building in the factory and offers storage spaces for 800 vehicles. The special challenge in this project was the integration of the high -bay warehouse into the existing factory premises and the consideration of the cramped space. The high -bay warehouse stands on a solid reinforced emphasis above the main logistics road, which is an innovative solution to the spatial problem. The approximately 30-meter-high reinforced concrete outer walls are stiffened via the bulkhead walls between the warehouse shelves. Due to the dense development in the building ground and the strict requirements for the stability and deformation of the shelf system, the building was founded on a 2 meter high reinforced concrete grate on 16 meter long bored piles with a diameter of one meter. This example shows how complex and demanding the construction of high -beam bearings can be, especially in urban industrial environments.

Daimler, another automobile giant, has also invested in the expansion of his global logistics center in Germersheim. A high-bay warehouse with over 80,000 square meters of storage space was built on a open space on the factory premises by the end of 2018, equipped with the latest conveyor and warehouse technology. Daimler AG invested around 100 million euros for construction. This logistics center serves as a central turntable for the global spare parts logistics of Daimler and shows the importance of high -bay bearings for global supply chains in the automotive industry.

Plastic and construction industry: store bulky goods efficiently

In the plastic and construction industry, industries that often have to do with bulky and voluminous goods, there are significant investments in high-bay warehouse. This is about storing large quantities of products in a space -saving and efficient manner in order to release production areas and optimize logistics processes.

The manufacturer of plastics groku plastics plans to expand his headquarters in Holte-Stukenbrock Castle by building a second high-bay warehouse. The 40 -meter -high building with a base area of ​​2,150 square meters will offer space for 12,500 plastic buckets of all kinds. After commissioning the new warehouse, the previous warehouse is to be abandoned and the vacancies that have become free to expand the production should be used. This is a typical example of how high -bay warehouse can help compact production locations and create valuable production areas.

Gealan window systems, a leading manufacturer of plastic profiles for windows and doors, is building a fully automated high-bay warehouse at the Tanna location. With costs of around 14 million euros, this is one of the largest individual investments in the company's history. The high -bay warehouse is designed as an automatic long -quality bearing that optimally uses the existing room. Due to the height, a lot of volume can be stored on a minimal stand. Long goods stores are special high -bay warehouse that are optimized for storing long, bulky goods such as profiles, pipes or poles.

In the building materials industry, the roof tile manufacturer Erlus built a pioneering high -bay warehouse at the Neufahrn location. As the world's first roof tile manufacturer, Erlus has decided to automate the logistics of roof ceramics and accessories. The automated high -bay warehouse is carried out in siloba, is around 30 meters high and offers space for around 8,400 pallets. With this new logistics center, Erlus sees itself as a pioneer in the industry and, as one of the first, relies on automated warehouse and picking technology for roof ceramics. The siloba way, in which the shelf scaffolding at the same time forms the load -bearing structure of the building, is a particularly space -saving and cost -efficient construction for high -bay warehouse.

Consumer goods and pharmaceutical industry: high envelope speed and sensitive products

In the consumer goods and pharmaceutical industry, in which high envelope speeds, short product life cycles and often sensitive products are characteristic, high-bay warehouses also play an important role.

Beiersdorf, the consumer goods group behind brands such as Nivea and Hansaplast, invests over 200 million euros in a new hub for its central European supply chain network in the north of Leipzig. A planned 25 meter high high -bay warehouse with around 125,000 fully automated pallet parking spaces will be the world's largest and most powerful warehouse in Beiersdorf. This camp will take on a central function in the European logistics of Beiersdorf and ensure the supply of the markets in Central Europe.

Previously, Beiersdorf had already built a hazardous substance high-bay warehouse in which two previously operated camps could be merged. In addition to economic aspects, the focus was on security when planning and establishing, since a new accident regulation placed increased safety requirements for the storage of products with inflammatory ingredients. Hazardous substances are special high -bay warehouse that are equipped with additional safety measures to minimize the risks of storing dangerous substances.

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• Real chain chaos: How market fragmentation endangers food and pharmaceutical security (and what we can do about it)

Technical features and advantages of modern high -bay warehouse: more than just high shelves

High -bay warehouse is far more than just "high shelves". They are characterized by specific technical features that make them so attractive for a wide variety of industries. These properties contribute significantly to the increase in efficiency, cost reduction and optimization of the logistics processes.

Space optimization and increase in capacity: vertical storage as a key to efficiency

A high-bay warehouse is defined as a warehouse with shelves from a height of 12 meters, which usually offers several thousand pallet storage spaces. The main advantage is the optimal use of the existing space. Due to the vertical construction, a maximum layer of layers can be realized on a minimal stand. In times of rising property prices and limited area resources, this is a crucial competitive advantage.

The example of the Kaufland logistics center in Donnersdorf, where the extended and fully automated high-bay warehouse protrudes 37 meters and offers space for 24,800 additional pallets, impressively illustrates this. 160 pallets can be outsourced and outsourced within an hour. This high cover speed is another major advantage of modern high -bay warehouse, which contributes to the acceleration of the logistics processes.

At Seeberger, too, the new high -bay warehouse with a height of 45 meters achieves a considerable increase in the storage capacity. The vertical construction enables a space -saving warehouse solution and the implementation of large storage capacities on a little area. The situation is similar at Beiersdorf, where the planned high -bay warehouse in Leipzig will offer around 125,000 fully automated operating pallet spaces.

Automation degree and technology: robots take over the helm

Another characteristic feature of modern high -bay warehouse is the high degree of automation. The times of manual warehouse work are largely over in modern high -bay bearings. Instead, complex, computer -controlled systems and robots take over the warehouse processes.

At Kaufland in Geisenfeld, the pallets are automatically stored by shelf operating devices into the high -bay warehouse after delivery and kept there until the goods are required. Depaleting, i.e. the unloading of the pallets, is also largely automatic. Twelve robot girely farms then put together the pallets individually and order the goods so that the employees in the branches can clear them directly in the correct order. This intelligent picking not only optimizes the warehouse process, but also the processes in the branches.

The autonomous and manually packed pallets are packed and foiled fully automatically and then transported in the right order via autonomous transport vehicles towards the goods output. The transport robots, often also known as automated guided vehicles (AGVS), have the most modern sensors, cameras and engine technologies that help them track the optimal route and safely to navigate people and objects. These driverless transport systems are a key element of automation in modern high -bay bearings and contribute to the efficiency and flexibility of internal logistics.

At Seeberger, a state-of-the-art high-bay bearing solution with a special “Hot Zone” buffer is developed for the new high-bay warehouse, which is designed for 500 pallets. This “hot zone” serves as an intermediate buffer for goods that are needed particularly quickly. The overall solution includes “Vectura” shelf control units, “Promino” funding systems, vertical lifts and the “Synq” toilet software. “Vectura” shelf control units are high-performance devices that were specially developed for use in high-beam bearings. “Promove” conveyor systems ensure a smooth material flow within the warehouse. Vertical lifts enable the quick and efficient transport of goods between different storage levels. And the “Synq” toilet software (Warehouse Control System) is the brain of the warehouse that controls and optimizes all processes. This technological complexity illustrates how highly developed modern high -bay warehouse is.

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• Stock at the limit? Warehouse automation: warehouse optimization vs. retrofit – the right decision for your warehouse

Energy efficiency and sustainability: Green logistics in focus

Modern high -bay warehouse is increasingly being designed taking into account sustainability aspects. The trend is clearly towards “green logistics”, in which energy efficiency and environmental compatibility are in the foreground.

In its new high -bay warehouse, Seeberger relies on innovative facade cladding, which ensures a stable temperature spectrum inside the warehouse both in summer and in winter. This means that active cooling of the warehouse can be avoided, which significantly reduces energy consumption. As part of the sustainability strategy, photovoltaic modules are also used on the new building, which add around 1 megawatt (peak) performance to the already installed photovoltaic areas on the existing buildings. The use of renewable energies and the reduction of energy consumption are central elements of sustainable warehouse logistics.

Swisslog, a leading provider of warehouse automation solutions, developed a photovoltaic solution for Seeberger in the form of a PV system attached to the roof and facades. The facade concept increases the production of green energy via the side walls of the building and thereby reduces the thermal energy input into the high-bay warehouse. This makes active cooling of the building superfluous to comply with the temperature range of five degrees Celsius to 25 degrees Celsius. This example shows how innovative building technology and renewable energies can go hand in hand to make high -bay warehouse more sustainable.

Kaufland achieves an annual saving of around 446,000 kilometers of a journey through 3.3 tons by expanding its high-bay warehouse in Donnersdorf in Donnersdorf. These impressive numbers underline the ecological advantages that can be achieved by optimizing logistics processes and the use of high -beam bearings. Due to the more efficient storage and picking, transport routes can be shortened and empties can be avoided, which leads to significant savings in fuel consumption and emissions.

Economic aspects and investment volume: high costs, high benefits

The construction of high -bay bearings is undoubtedly a considerable investment. The cost of planning, construction, technology and automation can be considerable. However, these investments are usually justified by long -term efficiency increases, cost savings and competitive advantages.

Investment volume across industries: million investments for the logistics of the future

The investment volumes for high -bay warehouse vary significantly depending on the industry, size, degree of automation and technological equipment. However, the examples from the article show that there are usually millions of investments.

Daimler invested around 100 million euros for the construction of the high -bay warehouse in Germersheim. Gealan estimates his fully automated high -bay warehouse at the Tanna location of around 14 million euros. In Erlus, the investment for the new logistics center is in a lower double-digit million amount. Beiersdorf is investing over 200 million euros in a new hub for its Central European Supply Chain network in the north of Leipzig, whereby the high-bay warehouse is making a significant part of this investment. Porsche invests around 250 million euros for its construction work, which also includes two new high -bay warehouse.

These examples make it clear that investments in high -bay warehouse are considerable across industries. The exact height depends on the specific requirements and the scope of the respective project. Size, degree of automation, complexity of technology and structural peculiarities affect the costs significantly.

Economic advantages and increase in efficiency: long -term return through optimized logistics

Despite the high initial investments, the economic advantages of high -bay bearings justify these expenses in many cases. The long -term efficiency increases and cost savings can significantly overcompensate the initial investments about the useful life of the warehouse.

At Beiersdorf, the internal logistics between two neighboring camp areas led to considerable additional effort, since the two camps used to belong to two independent business areas and were therefore designed for separate operation. This caused not only additional work traffic, but also a lack of inventory and warehouse transparency. By merging in a new hazardous substance high-bay warehouse, these problems could be resolved. The improved warehouse transparency and the reduction of work traffic lead to direct cost savings and more efficient logistics.

Even at Kaufland in Donnersdorf, the expansion of the high -bay bearing led to a significant increase in efficiency. Due to the improved logistics, around 446,000 kilometers of driving distance were saved annually, which, in addition to reducing CO₂ emissions, also leads to significant cost savings. Less transport kilometers mean lower fuel costs, less maintenance costs for transport vehicles and a lower environmental impact.

In the event of Erlus, the new high -bay warehouse improves working conditions for employees, the loading process is optimized, the inventory is stored exactly and noise emissions are also reduced. The principle “The goods come to humans, no longer reversed” leads to a significant increase in efficiency in the logistics process. More ergonomic jobs, optimized processes, precise inventory management and lower noise pollution contribute to higher employee satisfaction, lower error rates and an overall more efficient warehouse logistics.

Suitable for:

• High-bay warehouse consulting & planning: Automatic high-bay warehouse – optimize pallet warehouse fully automatically – warehouse optimization

Future trends and development perspectives: the logistics of tomorrow at a glance

The development of high-bay bearings is closely linked to the overarching trends in the logistics and automation industry. Several future -oriented aspects are already emerging and will significantly shape the development of high -bay bearings in the coming years.

Integration into digitized supply chains: the warehouse as part of the digital ecosystem

Modern high -bay warehouse is increasingly integrated into fully digitized supply chains. They are no longer isolated island solutions, but become integral components of a comprehensive digital ecosystem.

At Alpenhain, the flow of goods is completely automated and integrated into the ERP system (Enterprise Resource Planning). Freshly arriving from the production, finished goods arriving is abandoned via a common storage point and then stored according to the requirements. The seamless integration into the ERP system enables real-time stock management, optimized order processing and improved planning of the storage capacities.

At Kaufland in Geisenfeld, integration into digitized processes is also a central aspect. Fully automatic picking and transport via autonomous transport vehicles are closely linked to the overarching logistics and ERP systems. The digital networking enables transparent flow of goods, efficient control of the warehouse processes and optimal use of the storage capacity.

Flexibility and adaptability: bearings that can adapt

An important trend is the increasing flexibility and adaptability of modern high -bay warehouse. Logistics systems must also be flexible and reactionable in a rapidly changing world in which markets and demand fluctuate.

At Alpenhain, the entire high -bay warehouse is designed as a freezer. As a result, the company can react flexibly to fluctuations in demand - regardless of whether simply cooled or frozen products are in demand. It is possible without greater effort to increase or reduce the number of frozen parking spaces. This flexibility is a great advantage in the food industry, in which seasonal fluctuations and short -term changes in demand often occur.

With its “Flexiline” for two -door sports cars, Porsche relies on a variable production method in which driverless transport vehicles replace the classic assembly line. This development is closely linked to the logistical processes, which are supported by the new high -bay warehouse. Flexible production also requires flexible logistics systems that can quickly adapt to changed production plans.

Sustainability as a central factor: green logistics becomes the standard

Sustainability is becoming increasingly important when planning and operating high -bay bearings. What was once a “Nice-to-Have” is increasingly developing into a “must-have”. Companies recognize that sustainable logistics are not only ecologically sensible, but also economically advantageous.

In its new high -bay warehouse, Seeberger consistently relies on an energy -efficient construction with photovoltaic modules and special facade cladding, which makes active cooling superfluous. This development shows that ecological aspects are increasingly in the foreground and innovative technologies are used to make high -bay warehouse more sustainable.

Kaufland achieves a significant reduction in CO₂ emissions by optimizing its logistics processes with the extended high-bay warehouse. This makes it clear that sustainability aspects are taken into account in the planning of high -bay bearings across industries and that companies are actively working on minimizing their ecological footprints.

High -bay warehouse as a key technology for the future

The cross -industry analysis of the use of high -bay bearings in German industry clearly shows that this technology plays a central role in modern logistics concepts in almost all branches of industry. From the food industry to the automotive industry to the plastic, construction and consumer goods industry, companies use the diverse advantages of vertical storage to reduce their logistics processes more efficiently, to reduce costs and to strengthen their competitiveness.

The technological development of high -bay bearings is characterized by continuous progress in the areas of automation, digitization and sustainability. The degree of automation will continue to increase, integration into digitized supply chains becomes even narrower and the aspect of sustainability will come into focus even more. Energy -efficient construction methods, the integration of renewable energies, intelligent control systems and resource -saving operating processes will define the standard for modern high -bay warehouse in the future.

The flexibility and adaptability of high -bay bearings will be further improved in order to meet the constantly changing requirements of the market and the individual needs of companies. Modular construction methods, flexible automation solutions and intelligent software will make it possible to adapt high -bay warehouse even better to specific requirements and to react quickly to changes.

The cross -industry use of high -bay bearings underlines the universal applicability of this technology and leaves no doubt that it will continue to play a key role in industrial logistics in the future. Companies that invest in this technology not only improve their logistical processes and reduce their costs, but also strengthen their competitiveness in an increasingly digitized, globalized and environmentally conscious market environment. High -bay warehouse is therefore not only an instrument for increasing efficiency, but also a strategic investment in the future of German industry.

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