Central warehouse optimisation with STILL: Automation increases efficiency, safety and flexibility

European fastener specialist Fabory has automated its large warehouse in Tilburg. The new warehouse increases efficiency while providing greater safety and flexibility during peak periods. And the success speaks for itself: Fabory is already planning further automation projects in cooperation with the STILL specialists.

The peace and quiet at Fabory’s new large warehouse in Tilburg is striking. The four automated STILL EXV iGo high lift pallet trucks glide smoothly back and forth between the goods receiving area, the storage area and the palletising robot. Just as quietly, the three automated STILL MX-X iGo very narrow aisle trucks ensure that all the pallets end up in the right place. They do this by driving unmanned through 19 of the 21 aisles, covering some 28,000 bays. Two further aisles are reserved for manual operation – but the automation is working so well that this will soon be reduced to one aisle. From this central warehouse, Fabory supplies its three European distribution centres (UK, Portugal and Czech Republic) and ensures that the picking areas at the various sites always have sufficient stock. Fabory’s product range comprises around 450,000 items, 100,000 of which are stored in Tilburg.

Proven concept

“We have been enjoying this peace and quiet since October 2023, when we commissioned the new warehouse,” says Fabory Logistics Director Joost Jansonius. “Previously, the warehouse was spread over two locations in Tilburg, and we had daily shuttle services running back and forth. That was less than ideal. If we wanted to achieve our growth targets, we had to make some major improvements.”

A range of different storage systems and suppliers were evaluated before the company settled on the new concept. Fabory was looking for a high degree of automation combined with a high storage density and individually accessible pallet bays. “The solution offered by our preferred supplier, STILL, was the best fit for us,” adds Fabory Project Manager Leon Broere. “STILL had already implemented a similar warehouse at Tarkett in Waalwijk which was exactly what we were looking for. This proven concept was the deciding factor.”

The new 12-metre-high warehouse is where Fabory receives the goods delivered by its suppliers. The deliveries arrive on mixed Euro pallets containing up to 40 Fabory products. Unmixed deliveries are received, repacked and processed on the other side of the distribution centre.

Optimal site management

In the large new warehouse, the containers and trucks are unloaded manually using an STILL EXH-SF – a low lift pallet truck with a stand-on platform. As the truck passes the loading ramp, a fixed scanner automatically reads the pallet label. The operator then places the pallet at a defined handover position in the goods receiving area and scans the corresponding QR code for the item. From this point on, the STILL system takes over control. STILL’s transport control system receives the required transport orders for the various storage and retrieval processes from SAP. First, the automated high lift pallet trucks takes the pallet to the contour check, where a weight check is also carried out at the same time. iGo systems then assigns the optimal storage location in the racking system based on the storage height, weight and ABC classification. If any problems are identified, they can be remedied manually at the specially set up rework stations. Leon Broere points to the screen: “STILL has programmed a user interface that is practical and easy to use.”

Up to 300 double cycles at peak times

The automated high lift pallet truck EXV iGo takes the released pallets to the correct transfer station at the top end of the row of racking. The MX-X iGo very narrow aisle truck, which is also automated, collects the pallet from here and places it in the correct location. When the very narrow aisle truck needs to change aisle, it does so at the end of the rack. This ensures that the paths of the automated MX-X iGo and EXV iGo do not cross. If the trucks are inactive for an extended period of time or the battery reaches a defined state of charge, they go independently to their parking position, where they are automatically charged via a ground contact. This means that they are ready for use around the clock.

When the pallets are unloaded, the transport control system ensures that the automated high lift pallet trucks provide the correct pallets for the forklifts. These trucks then deliver the pallets to the palletising robot, which places the packaging units individually onto a conveyor belt. From here, the items are transported, for example, to the automated small parts warehouse. The entire system is designed for an average daily handling volume of 150 pallets, rising to 300 pallets in double cycles at peak times, with empty runs virtually eliminated.

Joint workshops – vital for rethinking processes

“We really enjoyed working with STILL,” says Leon Broere. “We appreciated the excellent support we received from project manager Yorick Oosthoek, during the installation process, as well as the open communication throughout. What’s more, we stayed on schedule and within budget.” Yorick accepts the compliment with a smile. “Automation has a significant impact on the logistical process and the organisation. It’s very important for us to accompany the customer through this process. Not just when installing the system, but especially when rethinking how they work. That’s why we organise workshops where we go through the entire process together, from start to finish. We work together to find the optimal solution.”

Logistics Director Joost Jansonius: “Thanks to the new large warehouse, we have better inventory management, we are cutting costs just as we wanted to, we have more flexibility at peak times, and delivery times have fallen from one to two days to two to three hours – and our customers are noticing the difference. And the warehouse environment is now much safer for people and machines.”

“Automation is helping us to find suitable team members, because that is a real challenge,” adds Leon Broere. “We run this warehouse with two employees per shift and two shifts on five working days. Everyone is very satisfied. What’s more, we recently signed a contract with STILL to extend automated transport to other parts of our central warehouse. We plan to do this over the next two years. After all, progress in automation is not just limited to greenfield projects, major advances can also be made in brownfield plants.”