Jungheinrich Expands Keller & Kalmbach’s Central Warehouse

Keller & Kalmbach, specialist in fastening elements, fastening technology, and intelligent C-parts management, is expanding the capacity of its central warehouse and distribution center in Hilpoltstein, Bavaria for the second time. Jungheinrich has been commissioned to build four new aisles in the cardboard warehouse by the end of 2023, alongside the six existing aisles of the automatic small parts warehouse (AKL).

(Hamburg/Hilpoltstein) The partnership between Jungheinrich and Keller & Kalmbach has a tradition: Already in the first construction phase of the central warehouse, which went into operation in 2009 and marked Keller & Kalmbach’s entry into automation systems, the family-owned company with over 140 years of history relied on Jungheinrich. Due to the successful collaboration, Jungheinrich was also entrusted with the first expansion phase in 2016. Now, the order for the second phase has followed.

“Over the years, we have continuously worked together to optimize the warehouse and already doubled the capacity with the first expansion in 2016,” reports Robert Schad, Senior Project Manager Technical Sales ASRS at Jungheinrich. “At that time, we had already planned the next expansion, which is now being realized.” This is because Keller & Kalmbach had anticipated strong further growth during the first expansion six years ago, which has indeed occurred and requires additional storage capacity in the AKL: With a revenue increase of 20 percent to 350 million euros, the full-service provider with 900 employees recorded a record in 2021, and Keller & Kalmbach also acquired several companies last year. All of this made the expansion essential.

Almost 80,000 Additional Cardboard Storage Spaces

Jungheinrich is creating a total of 79,968 additional cardboard storage spaces (+ 25 percent) through the expansion on the 44,000 square meter site in Hilpoltstein, where two shelf storage systems ensure smooth material flow alongside pallet and cardboard storage. Thanks to appropriately designed picking workstations, pallets and cardboard can be processed together and customer requirements can be implemented precisely. Keller & Kalmbach serves customers from the automotive and commercial vehicle industry, mechanical and plant engineering, as well as the railway, agricultural, and construction machinery industries.

Four New Aisles to be Connected

For the current warehouse expansion, Jungheinrich is supplying four stacker cranes and the cardboard conveyor technology, each including control and visualization. Additionally, the steel construction for the shelves (55 x 12.5 x 14.3 meters), project management, and the Jungheinrich WMS are part of the delivery from Hamburg. Since the warehouse was designed with foresight in 2016, space for the four new aisles, the system for the conveyor technology in the front zone, and corresponding constructions are already available for the current expansion. The new aisles will be connected to the existing conveyor technology and the warehouse management software.

Advantages of Automation Recognized Early

But even now, one of the most comprehensive WMS from Jungheinrich is in use in Hilpoltstein. Furthermore, Keller & Kalmbach, as a trendsetter, recognized the advantages of automation early on, such as high efficiency, precision, and scalability. “Not only has Keller & Kalmbach grown with us over the years, but we have also grown with them,” explains Schad, referring to the fact that numerous Jungheinrich customers and interested parties have visited the central warehouse south of Nuremberg as a successful reference.

Transparency and Mutual Trust

We have a long-standing and developed partnership with Jungheinrich, characterized by transparency and high mutual trust. This is extremely important to us, and we are very satisfied. In this long relationship, there is a service contract with Jungheinrich, which now also applies to the new aisles. And the next joint project is already taking shape: after the cardboard warehouse, the capacities in the pallet warehouse are also to be expanded in the future. The silver anniversary is therefore approaching.

Photo: © Jungheinrich