Roads to the automated warehouse

Digitization, flexibility, availability and smart warehouse control are currently on the agenda of many companies in the food industry. Solutions for automating material handling come into their own at the latest when a large number of items are stored and handled in multi-shift operation around the clock or in a limited space. When deciding which intralogistics system to use, it is important to consider not only storage capacity, but also the flow of goods, the number of item types available, and the company's supply chain requirements. Each system has certain characteristics that must be taken into account when looking for a solution to the problems of a particular warehouse. The good news: With their broadly based portfolios, the exhibitors at Anuga FoodTec are also popular partners when it comes to accompanying food producers on their way to efficient, sustainable logistics processes.

From this standpoint, automatic pallet storage systems are more universally applicable than any other storage technology. Whether in single-deep, double-deep or multiple-deep design, whether in deep-freeze environments down to minus 35 degrees Celsius or at normal temperature, whether as a flat or high-bay warehouse with a height of up to 45 meters - the automatic pallet warehouse is the all-rounder suitable for almost all types of food. The storage bays for pallets, pallet cages and individual carrier systems can accommodate loads of over three tonnes. Operated with automatic storage and retrieval machines or alternatively with shuttle systems, the automatic pallet warehouse stands for fast, resource-saving material flows.

But what components does a system of this kind consist of, at what point does their use make economic sense and what does the introduction process look like? At the Cologne exhibition centre, visitors can gain an overview of all the building blocks of successful intralogistics automation. These include, for example, rail-guided high-speed storage and retrieval machines (SRMs). As a key technology, they are always used where people, industrial trucks or autonomous mobile robots cannot access the warehouse due to narrow aisles. As single or double masters, they ensure more speed in the single, double or multiple-deep storage and retrieval of goods. A wide range of load handling attachments for different parking space depths are available for this purpose.

One of the most difficult challenges for food businesses is achieving more storage capacity in a limited space. A frequently chosen solution is the use of compact shuttle systems, as these optimise the available space, therefore creating room for a larger number of pallets. In contrast to a storage and retrieval machine, these are compact electric vehicles for the automatic loading of pallet warehouses. They move individually to each shelf row and can change levels as well as aisles. Thanks to their modular design, the systems can also be integrated into buildings that have unusual shapes. The storage and retrieval performance can be scaled by simply adding more shuttles. Vertical conveyors also allow the shuttles to be used on any shelf level, so that warehouses of any height can be equipped with shuttle systems.

For example, with its Aviator technology, Westfalia shows that the exhibitors at the Cologne exhibition centre are thinking beyond the classic storage and retrieval machines and are opening up new possibilities for automation. The main advantage here: The hall areas can still be walked on and driven over because the system does not require a track on the floor. In contrast to a floor-based storage and retrieval machine, the Aviator travels with its chassis and lifting gear on the top level of the warehouse. All storage bays on this level are retained. Cables lower and lift the load handling device within the racking aisle. The shelves and channels are controlled with the usual precision with the aid of intelligent automation technology.

When it comes to automating intralogistics processes in the company for a digital future, driverless transport systems (AGSs) are considered another pioneering solution. The "little helpers" optimise the material flow and compete with conventional industrial trucks, conveyor belts, continuous conveyors or electric overhead conveyors. With AGS, the number of empty and incorrect trips can be reduced to almost zero, because the vehicles automatically drive to the correct shelves.

Thanks to standardised interfaces, AGSs can be seamlessly integrated into existing warehouse processes. Multi-frequency guide wires and transponders in the floor ensure orientation in the aisles. The driving routes are integrated into the ongoing operations, so that warehouse structures and working areas remain intact. Equipped with appropriate safety features, they are the optimal choice for efficient mixed operation with manual vehicles and pedestrians in warehouses and production. However: An AGS can detect obstacles ahead but is not able to avoid them - that is, it stops until there is no longer any risk.

This is not the case with autonomous mobile robots (AMRs), which independently avoid people or objects and calculate the most efficient route to the destination using a recorded map of the surroundings. They are intended to make intralogistics even more flexible. According to the International Federation of Robotics (IFR), one in three professional service robots is now used to transport goods. For example, global sales of autonomous mobile robots increased by eleven percent to over one billion US dollars in 2020. Most of the units sold are used indoors - for example in production or in the warehouse. According to the IFR forecast, the market will continue to grow by up to 40 percent annually. The latest developments here include fully integrated combinations of a cobot and a transport platform.

Many food manufacturers also see mobile robots as a good opportunity to make their work processes more efficient and to counter the shortage of skilled workers. In contrast to driverless transport vehicles, they navigate freely within a defined area. This is ensured by intelligent 360-degree sensor technology, laser scanners, 3D cameras and a software algorithm that detects possible obstacles both horizontally and vertically and, if necessary, ensures that the AMR stops automatically before a collision occurs. Integrated collision detection ensures that the robots can work together safely and efficiently in dynamic environments. When picking-up the load carrier, the AMR is guided by its position and orientation. This makes them suitable in principle for all horizontal transport on the ground or pick-up and delivery services as carried out by people.

Especially when delivery points such as mixers are not arranged linearly, AMRs are an interesting variant. Appropriate dosing points can be approached, for example, by such an AZO vehicle controlled by laser navigation, which collects the raw materials precisely weighed according to the recipe. But AMRs are also suitable for machine loading as part of a tool change or for laboratory automation.

Jan Louwen, Global Head of AGV and Managing Director of the Stäubli site in Sulzbach-Rosenberg, also sees the versatility of such vehicles as an outstanding feature. "Our PF3 is a true all-rounder. For example, it can first be used to lift Euro pallets and then to move goods from A to B in production. These are strong arguments for users because they can cover different applications with one type of vehicle," says Louwen. With dimensions of 1,750 x 970 x 400 millimetres, the mobile transport platform fits into the dimensions of common industrial vehicles, but at the same time convinces with a high load capacity of three tonnes. Thanks to its standardised, scalable design in combination with countless application possibilities, the PF3 is the flexible all-rounder in the intralogistics and production environment.