Frankfurt am Main, Germany – Mainova AG, a major energy supplier serving over one million people with electricity, gas, heat, and water, has consolidated its spare parts logistics operations into a new Regional Warehouse East in Frankfurt. The facility utilizes advanced automation and storage solutions from Jungheinrich to enhance efficiency, improve supply security, and optimize space utilization. The project represents a significant investment in infrastructure designed to streamline the delivery of critical components for the region’s energy network.
The new warehouse, encompassing approximately 6,200 pallet storage spaces and reaching a height of up to 17.1 meters, is centered around a narrow-aisle storage system. This design maximizes storage density while enabling quick and accurate retrieval of parts. Complementing the pallet storage is a small parts warehouse, extending 7.5 meters in height, designed for efficient order fulfillment of smaller components. The integration of these systems aims to provide a comprehensive solution for managing a diverse range of spare parts, from large equipment to individual components.
Automated Guided Vehicles and High-Rack Stackers
Central to the warehouse’s operation are two Jungheinrich EKX 516 trilateral trucks. These specialized vehicles are designed for navigating extremely narrow aisles, allowing for optimal use of vertical space. According to Jungheinrich, the EKX 516 boasts high positioning accuracy and energy-efficient drive technology, enabling economical operation even at significant lift heights. The EKX 516 is capable of lifting loads up to 3,500 lbs. And reaching heights of up to 472-511 inches.
The use of trilateral trucks, also known as reach trucks, is a key element in maximizing storage capacity within the narrow-aisle configuration. These vehicles can rotate their forks to load and unload pallets on either side, eliminating the demand for turning within the aisles. This design significantly increases storage density and reduces travel time for warehouse operators. The EKX 516’s advanced features contribute to a faster and more reliable parts retrieval process.
Compact Storage and Efficient Picking
Beyond the pallet storage, the Mainova warehouse incorporates eleven Jungheinrich vertical lift modules (VLMs) to manage small parts. These automated systems provide compact, secure storage and enable goods-to-person picking, bringing the items directly to the operator. This approach minimizes walking time and reduces the risk of errors, leading to faster order fulfillment. The VLMs are designed for quick access times, crucial for rapidly providing spare parts when needed, even with a high variety of items.
Vertical lift modules operate on the principle of automated carousels, storing items in trays that are retrieved and presented to the operator at an ergonomic height. This system not only saves space but also enhances worker safety and productivity. The integration of VLMs demonstrates Mainova’s commitment to utilizing cutting-edge technology to optimize its logistics operations.
Integrated Warehouse Systems
The new facility also includes a wide-aisle warehouse, serviced by a Jungheinrich EFG 425k electric four-wheel counterbalance truck. This truck is equipped with telescoping forks to handle double-deep pallet racking within the 10-meter high section of the warehouse. The Jungheinrich EFG 425k is designed for versatility and reliability in handling a variety of palletized loads.
For the storage of long goods, both in the new building and an adjacent existing hall, cantilever racking systems are employed. While the cantilever racking in the new building is also serviced by the EFG 425k, Jungheinrich, acting as general contractor, has provided a specialized vehicle from Hubtex to operate the cantilever racking in the existing hall, integrating this area into the overall warehouse concept. This demonstrates a comprehensive approach to managing diverse storage needs within a unified system.
Hazardous Materials Storage
A dedicated hazardous materials storage area has been incorporated into the new hall, featuring manually operated shelving for storing items such as oils and paints. This segregated storage area ensures compliance with safety regulations and minimizes the risk of accidents. The warehouse design prioritizes the safe and secure handling of all materials, including those requiring special precautions.
Project Goals and Benefits
Leonid Feldman, Project Manager and Civil Engineer/Architect at Mainova AG, stated, “With the new Regional Warehouse, we significantly increase the efficiency and supply security of our spare parts logistics and optimally utilize the existing property.” Sascha Kaden, Team Leader of Warehouse Management and future user of the facility, added, “Jungheinrich’s solution maps our very different storage requirements – from small parts to long goods – in a seamless system, creating the foundation for fast and reliable processes.”
The consolidation of spare parts logistics into a single, modern facility is expected to yield significant benefits for Mainova. These include reduced lead times for parts delivery, improved inventory management, and enhanced operational efficiency. By streamlining its logistics processes, Mainova aims to ensure a reliable supply of spare parts for its critical infrastructure, ultimately contributing to the stability and resilience of the region’s energy supply.
Future Developments
Mainova’s investment in the Regional Warehouse East reflects a broader trend towards automation and digitalization in the logistics sector. As companies seek to optimize their supply chains and improve responsiveness to changing market demands, the adoption of advanced technologies such as AGVs, VLMs, and warehouse management systems is expected to continue. The successful implementation of this project could serve as a model for other organizations looking to modernize their logistics operations.
The next step for Mainova will be the full integration of the new warehouse into its existing logistics network and the training of personnel on the new systems. Ongoing monitoring and optimization of the warehouse processes will be crucial to maximizing its benefits. Further updates on the performance of the facility and any planned expansions are expected in the coming months. Readers interested in learning more about Mainova’s operations can visit their official website at www.mainova.de/en/.
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