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SPAR Föderlach/Tann Fleischwerk
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Kaiser’s Tengelmann GmbH  Getränke-Industrie Hamburg H. Leiter Leergut SPAR Leergutmanagement Distillerie Franz Bauer Winery SPAR Föderlach/Tann Fleischwerk More references
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THE CLIENT
The SPAR Tyrol/Pinzgau Trade Association, founded in 1954, was renamed SPAR Österreichische Warenhandels AG on the merger of ten Austrian wholesale businesses in 1970. Today, SPAR is the largest domestic industrial business in Austria. With the wholesale and retail of foodstuffs – as well as the production of meat and sausage goods, wines, spirits, coffee and tea – SPAR offers an extensive range of products. With a conscious public awareness of domestic meat and sausage quality, SPAR produces meat and sausage for Austria under the TANN brand name. The main facility for this production was recently built in Föderlach, near Villach where a number of award-winning specialities are produced. The equipment and production processes of the TANN plant in Föderlach comply fully with the most stringent of EU standards. A programme of ongoing investment also ensures that TANN continues to meet the strictest of quality requirements. In addition to this main plant, each SPAR retail outlet in Austria is affiliated to a modern meat factory where an additional range of TANN sausage meat is produced and where particular attention is paid to regional specialities. Other tasks assigned to the retail outlets include the buying in of fresh meat and the correct butchering of meat for deliveries to more than 850 fresh meat departments within SPAR, SPAR Gourmet, EUROSPAR and INTERSPAR retail stores.
THE REQUIREMENT
With increasing demand as a result of Slovenia’s imminent entry to the EU, the TANN meat factory in Föderlach reached the limits of its storage capacity. The central task of KNAPP was therefore to realise a new, tailor-made storage facility with the aim of increasing the ability of the TANN plant to raise its output level. Optimum implementation of the task required a new, automatic high-bay pallet warehouse for sausage and meat products and a semiautomatic goods-to-man order picking system with pallet conveyors. Despite the prevailing space limitations for installing high-bay storage and order picking areas, the warehouse was to meet the stringent requirements of the future by providing an output of 220 pallets/hour.
THE SOLUTION
Realisation of this project placed high demands on the planning and implementation skills of KNAPP and tested fully the technical capabilities of the KISoft MOTION and CONTROL software products. The particularly challenging aspects of the implementation were the three key areas of the new warehouse: the automated and partly bidirectional pallet conveyor technology, the ergonomically designed order picking stations utilising hydraulic lift tables and the high-bay store which features two automatic stacker cranes sharing a single rail.
Optimising the pallet transport technology
Automatic pallet conveyor rapidly and securely links the four most important work areas in the TANN warehouse: the pallets are received at goods-in, transported to the order picking area, then taken into the highbay store and finally supplied to the dispatch area for shipping. To optimise use of the conveyor system, approximately 30% of the entire warehouse’s pallet transport – including the entire goods reception area – is bi-directional. Planning how to change over the direction of conveyor sections is one of the major tasks of the material flow computer (KISoft CONTROL).
Increasing the flexibility of picking areas through the use of lift table
After the curing phase – which the meat and sausage goods spend in the high-bay warehouse – the pallets are transported to the specially designed order picking platforms. To ensure efficient and ergonomic order picking, hydraulic lift tables raise the pallets to the appropriate working height. The picking operative can focus on his task without the need for stretching or strenuous lifting.
Increasing efficiency in the high-bay store
To ensure that goods are moved into and out of storage at intensive throughput levels despite the space limitations of the site, KNAPP devised a storage innovation – in the high-bay store two automatic stacker cranes operate at the same time on a single rail, sharing one input/output station. The zone around this input/output station is a potential ‘collision area’ for the two stacker cranes but its use is supervised by the operating software. To avoid conflicting activities, pallets are moved around the store during inactive periods. These controlled pallet movements from the collision area (buffer area) into the non-collision area (active area) are undertaken on the basis of access statistics. In addition to increased efficiency, intelligence is the second central element of the TANN warehouse. When brought into the high-bay, the pallets are stored strategically in those locations which require the minimum number of internal shifts in storage before subsequent removal.
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