Ingersheim, Germany – The Berrang Group, a leading wholesaler for mechanical fastening technology, has partnered with Exotec, a global leader in warehouse automation, to implement a cutting-edge, automated intralogistics system at its newly constructed warehouse in Ingersheim, Baden-Württemberg. The move aims to enhance the company’s just-in-time delivery capabilities to key industries including automotive, optoelectronics, medical technology, and mechanical engineering.
The implementation of Exotec’s Skypod system, finalized in December 2025, marks a significant investment in the future of Berrang’s supply chain. The new facility is strategically located to efficiently serve industrial customers in the region, responding to the increasing demand for rapid and reliable delivery of precision parts. This automation project underscores a broader trend within the manufacturing sector towards increased efficiency and responsiveness through advanced logistics solutions. The Skypod system is designed to handle a high volume of small parts, a critical component of Berrang’s business model.
Berrang Group’s Expansion and the Need for Automation
Founded in 1948 and headquartered in Mannheim, the Berrang Group has grown into a prominent supplier of C-parts – screws, nuts, bolts, and pre-assembled components – serving a diverse range of industries. With over 700 employees across twelve global locations, the company’s decentralized operational model prioritizes proximity to customers to ensure timely delivery. According to Exotec, this proximity is particularly crucial in the automotive industry, where just-in-time delivery is a competitive necessity.
The decision to build a new warehouse in Ingersheim was driven by the need to more effectively supply nearby industrial customers. As demand grew, Berrang recognized the limitations of its existing infrastructure and sought a sophisticated intralogistics solution to optimize its operations. The company’s search led them to Exotec and its Skypod system, which offered the scalability and speed required to meet their evolving needs. The Skypod system’s ability to handle a large number of small parts efficiently was a key factor in the decision-making process.
The Exotec Skypod System: A Deep Dive
Exotec’s Skypod system is a scalable robotics solution designed to optimize warehouse operations. The system utilizes autonomous robots that navigate a three-dimensional grid, retrieving and delivering items to workstations. As reported by Warehouse News, the Berrang Group’s installation features over 23,000 bins and 7,000 trays, reaching a rack height of nearly 12 meters. This configuration allows for a throughput of 137 bin movements per hour, significantly increasing the speed and efficiency of order fulfillment.
The Skypod system’s flexibility is a major advantage for Berrang, enabling the company to adapt to changing customer demands and product mixes. Andreas Essewein, Project Manager for Logistics and Operations Planning at Berrang, emphasized the system’s suitability for their just-in-time delivery requirements, stating, “The Skypod system is highly flexible and ideal for our just-in-time delivery requirements at Berrang, where every single minute matters.” The system’s ability to quickly locate and retrieve items minimizes order processing time and ensures that customers receive their parts when they need them.
Key Features and Benefits of the Skypod System
- High Throughput: Capable of handling 137 bin movements per hour, optimizing order fulfillment speed.
- Scalability: The system can be easily expanded to accommodate future growth and changing demands.
- Flexibility: Adaptable to a wide range of part sizes and configurations.
- Space Optimization: Utilizes vertical space efficiently, maximizing storage capacity.
- Reduced Labor Costs: Automation reduces the need for manual labor in picking and sorting processes.
Impact on Berrang’s Supply Chain and Regional Industries
The implementation of the Skypod system is expected to have a significant positive impact on Berrang’s supply chain, enabling the company to provide faster and more reliable service to its customers. By streamlining its warehouse operations, Berrang can reduce lead times, improve order accuracy, and enhance overall customer satisfaction. This, in turn, strengthens its position as a leading supplier of mechanical fastening technology.
Andreas Stöckl, EVP Sales at Exotec, highlighted the broader implications of the project, stating, “This project demonstrates the potential of the Skypod system for suppliers serving production and industry, even under the strictest requirements in highly specialised sectors, especially where the smooth supply of manufacturing facilities is paramount.” The success of the Berrang Group’s implementation could pave the way for wider adoption of automated intralogistics solutions within the region’s automotive, optoelectronics, medical technology, and mechanical engineering industries.
The new warehouse in Ingersheim is poised to become a critical hub for the supply of C-parts to regional manufacturers. By ensuring a consistent and reliable flow of components, Berrang is contributing to the overall efficiency and competitiveness of these industries. The automation project represents a strategic investment in the future of manufacturing and logistics in Baden-Württemberg.
Looking Ahead: The Future of Warehouse Automation
The Berrang Group’s adoption of the Exotec Skypod system is part of a larger trend towards increased automation in warehouse and logistics operations. Driven by factors such as rising labor costs, increasing customer expectations, and the growing complexity of supply chains, companies are increasingly turning to robotics and automation to improve efficiency and reduce costs. Logistics Matters reports that this trend is expected to accelerate in the coming years, with further advancements in robotics, artificial intelligence, and machine learning driving innovation in the field.
As warehouse automation technologies continue to evolve, we can expect to see even more sophisticated and integrated solutions emerge. These solutions will not only automate physical tasks but as well leverage data analytics and machine learning to optimize warehouse layouts, predict demand, and improve overall supply chain performance. The Berrang Group’s investment in the Skypod system is a testament to the transformative potential of warehouse automation and its ability to drive efficiency, innovation, and growth.
The next step for Berrang will be to fully integrate the Skypod system with its existing enterprise resource planning (ERP) and warehouse management systems (WMS) to create a seamless flow of information and optimize its end-to-end supply chain. Ongoing monitoring and analysis of system performance will be crucial to identify areas for improvement and ensure that the system continues to meet the company’s evolving needs. The company has not yet announced any further expansion plans, but the success of the Ingersheim warehouse could lead to similar automation projects at other Berrang facilities in the future.
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