Where Genetics Meets Logistics: Novogenia and KNAPP to Develop Smart Health Products Hub

Two Austrian trailblazers – one shared vision: Novogenia and KNAPP are planning an innovative logistics center to support the future of personalized health products. The biotech company Novogenia, a member of the DARWIN AG, is a leading provider of genetics-based health products. They analyze a person’s genetic makeup to tailor nutritional supplements and cosmetics to the specific needs of this individual. Prompted by steady growth and rising international demand, Novogenia has chosen to automate their logistics processes extensively, trusting in KNAPP as a tech partner. The new development in Hallwang near Salzburg, Austria will bring their complex manufacturing and global distribution to a new level – efficient, scalable and ready for the future. The new system is due to start operation at the end of 2026, and is certain to be a showcase for the successful application of intelligent logistics to the world of biotechnology.

Three worlds, one system

The biggest challenge that presented itself was to mesh three fundamentally different divisions: lab, manufacturing and distribution, with distribution focusing mainly on the US market. This complex logistical balancing act is elegantly maintained through technology and know-how. The different products needed for a customer order are produced separately and stored until they all are ready. Only then are the products brought together automatically to fulfill the customer order – making complexity simple. Within 20 minutes, the genetic report, the supplement and the cosmetic product arrive at the pack station ready for global shipping. Up to 8,000 packages will be shipped from the Hallwang logistics center every day, which corresponds to an annual turnover of about 500 million euros. “Our customers will enjoy speed and precision like never before. The new infrastructure means that customers will receive their genetic analyses and personalized health products in a mere five days – light-years ahead of the six to eight weeks that are common on the market”, enthuses Daniel Wallerstorfer, molecular biologist and CEO of Novogenia.

Sophisticated technology

Measuring 11,000 m², or about 118,000 sq ft, the new logistics center will feature cutting-edge technology. The backbone of the logistics system is the Evo Shuttle with two rack line systems and triple-deep storage capacity. In addition, Open Shuttles and an Open Shuttle Fork will transport containers and pallets respectively, boosting flexibility and scalability. Combined, these systems can bring together products from separate production lines automatically. The manufacturing areas on different levels of the warehouse are seamlessly connected through two central pre-zones, a big highlight in the new system. At these pre-zones, the Open Shuttles can pass containers on to the conveyor system, and also pick them up independently. Watching over all these processes is the KNAPP software KiSoft One, a central platform for seamless control. A unique feature of this solution: The Open Shuttles use the existing elevators for people and goods to move pallets and containers between levels. This clever detail makes optimal use of the infrastructure that is already there. The new system is not only powerful, but also ready for the future: The Open Shuttle fleet can be expanded as needed, and Novogenia can adapt the travel paths and processes as they see fit. “We are especially pleased with the way the Open Shuttle Fork and the Evo Shuttle lift work together, enabling us to move pallets to the basement fully automatically while keeping them available to the system at all times”, says Daniel Wallerstorfer. KNAPP is also keen to highlight how unique the solution is: “The interplay of stability, flexibility and scalability is what makes this a truly one-of-a-kind project. We haven’t invented any new technology here, just combined established ones in an innovative way”, states Johannes Kompek, Senior Sales Engineer at KNAPP.

About KNAPP

KNAPP is the technology partner for intelligent value chains. Headquartered in Austria, the KNAPP group provides all-in-one solutions for automation and digitalization, from production and distribution to the point of sale. Excellent service and long-term collaboration make KNAPP the strong partner behind the success of their customers in the healthcare, retail, food retail, fashion, wholesale and industry sectors.

About Novogenia

Novogenia is a member of the DARWIN AG and European market leader for personalized health products. Headquartered in Austria, Novogenia develops customized nutritional supplements, cosmetic products and health solutions based on genetic analyses. Their products are carefully tailored to suit the genetic needs of the specific individual. Within the DARWIN AG, Novogenia combines scientific excellence with technological innovation and sets new standards in preventative healthcare and personalized product development.