Poland: Fully automated high-bay warehouses and pallet storage solutions and consulting, construction, implementation & installation – Image: Xpert.Digital
Efficiency in logistics: Why Polish companies are relying on fully automated warehouses
The future of warehousing: Polish companies are investing in automation
Polish companies are increasingly relying on fully automated high-bay warehouses and pallet storage solutions to boost their logistics efficiency. These modern systems offer numerous advantages, including optimized space utilization, faster processes, and increased productivity. The following provides a comprehensive overview of these technologies, supplemented by interesting insights into current projects and their benefits.
Fully automated high-bay warehouses
High-bay warehouses are specially designed storage structures that can typically reach heights of up to 45 meters. They enable space-saving storage of pallets or wire mesh containers and are often equipped with storage and retrieval machines that ensure fast storage and retrieval. These warehouses offer high storage density and are frequently modular in design, allowing them to be adapted to individual requirements.
These warehouses are automated through the use of technologies such as stacker cranes, conveyor systems, and warehouse management software. These systems coordinate the flow of materials and enable precise control of all processes.
Advantages of automation
Automated high-bay warehouses offer numerous advantages:
- Optimal use of space: Vertical storage maximizes the use of available space.
- Increased efficiency: Automated processes reduce errors and accelerate workflows.
- Safety: Minimizing manual intervention reduces the risk of accidents.
- Cost savings: In the long term, automated systems reduce operating costs through reduced personnel and energy costs.
- Flexibility: The systems can be adapted to different industry requirements, e.g. for frozen products or hazardous goods.
Examples from Poland
Ceramika Paradyż: Tailor-made solution for the ceramics industry
Ceramika Paradyż has built an automated, silo-style high-bay warehouse. This warehouse has a capacity of over 20,200 pallets and is 25 meters high. It comprises eight aisles with single-deep racking on both sides. The integration of Easy WMS software enables efficient management of warehouse processes.
Particularly noteworthy is the two-story building structure at the warehouse entrance. While goods receiving and dispatch are organized on the lower level, the upper level is used for order picking. This division significantly increases productivity.
Amica: Poland's tallest high-bay warehouse
Amica, a leading manufacturer of household appliances, has built Poland's tallest high-bay warehouse, standing at 45 meters. This warehouse offers space for 25,760 pallets and can store approximately 230,000 electrical appliances. The stacker cranes enable double-deep storage with a load capacity of 2 x 550 kilograms per unit.
The high system performance allows for the retrieval of up to 160 pallets per hour and the storage of 120 pallets. Control is managed via a control center that is seamlessly integrated into the company's SAP system.
Julius Blum GmbH: Expansion of logistics capacities
Furniture fittings manufacturer Julius Blum GmbH has built a new high-bay warehouse near Poznań, comprising eight storage and retrieval machines. In addition to warehouse automation, the existing conveyor technology was also modernized to ensure a smooth flow of materials between the individual logistics areas.
The storage and retrieval machines used are characterized by their durability and modular design, making them particularly adaptable. This system not only improves storage capacity but also the efficiency of the entire logistics chain.
Technological innovations
Modern high-bay warehouses rely on advanced technologies such as:
- Storage and retrieval machines: These machines move vertically and horizontally along the shelves and handle the storage and retrieval of pallets.
- Conveyor technology: Various conveyors transport goods within the warehouse system.
- Warehouse Management System (WMS): These systems control all processes in the warehouse and ensure transparency.
- Material flow control: This technology optimizes the flow of goods within the warehouse.
The process: From consultation to installation
The success of a high-bay warehouse or pallet warehouse begins in the planning phase. Polish companies place great emphasis on precisely analyzing their customers' needs and developing the best solutions together. The process can be divided into several steps:
1. Consultation and needs assessment
In the first phase, the customer's specific needs are determined. This includes analyzing the available storage space, the products to be stored, and the desired throughput. The goal is to develop a solution that is optimally tailored to the customer's needs.
2. Planning and Design
During the planning phase, engineers create detailed plans for the warehouse. State-of-the-art CAD software and simulation tools are used to optimize the system's functionality and efficiency. Particular attention is paid to the integration of automated systems such as stacker cranes, conveyor belts, and warehouse management software.
3. Construction and manufacturing
Polish companies rely on high-quality materials and state-of-the-art manufacturing technologies. The components for the high-bay warehouses are prefabricated in specialized workshops, enabling rapid on-site assembly.
4. Installation and commissioning
Installation is carried out by experienced teams who ensure that the system functions precisely and reliably. After installation, the system undergoes extensive testing to ensure that all components work together flawlessly.
5. Training and Maintenance
After commissioning, customers receive comprehensive training to ensure optimal use of the new system. Furthermore, many Polish providers offer long-term maintenance contracts to guarantee the system's longevity and reliability.
Challenges and solutions
Despite their advantages, automated high-bay warehouses face challenges such as high investment costs and complex implementation. To overcome these hurdles, suppliers offer customized solutions that are precisely tailored to their customers' needs.
One example of this is the possibility of gradually automating existing manual storage systems or replacing individual components such as stacker cranes. This allows companies to better plan their investments while simultaneously benefiting from the advantages of automation.
Future prospects
The demand for automated warehouse systems will continue to rise, especially in the context of Industry 4.0. Technologies such as artificial intelligence (AI) and machine learning could enable even more precise forecasts for inventory levels in the future and further increase efficiency.
Furthermore, sustainable solutions such as energy-efficient storage and retrieval machines or CO₂-neutral logistics centers are expected to gain in importance.
Automation increases their competitiveness
Fully automated high-bay warehouses are setting new standards in the logistics industry. They offer not only high efficiency and safety, but also customized solutions for diverse industry requirements. Projects such as those by Ceramika Paradyż, Amica, and Julius Blum impressively demonstrate how companies can increase their competitiveness through automation. Looking ahead to future innovations, this technology will remain a key component of modern logistics strategies.
Suitable for: