Kardex Mlog Builds Two Automatic Buffer Warehouses for BASF

Kardex Mlog has built two identical automatic buffer warehouses for the chemical company BASF, including warehouse management and conveyor technology for connecting incoming goods and production. The two dynamic replenishment warehouses for raw materials offer a capacity of 272 special load carriers each, with a weight of up to 1,350 kg, and are operated around the clock, seven days a week.

(Neuenstadt) A central component of the extremely compact solution is the Kardex MTower type lift beam storage developed by Kardex Mlog, which is specifically designed for narrow and high storage halls. The principle is based on a vertically guided lift beam on which a distribution cart moves. The automatic pallet storage operates faster and more efficiently than other storage concepts based on a storage and retrieval machine.

With the two new raw material warehouses, BASF decouples external delivery from production supply. The two identical Kardex MTower systems are located in adjacent buildings and enable the automated supply of raw materials to a facility. “The extremely low footprint and the variable construction height of the Kardex MTower were decisive factors, allowing us to optimally utilize the existing buildings,” explains Aaron Werner, Engineer, BASF SE. The 24.7m high warehouses are connected to two building floors via conveyor technology, eliminating the need for an additional lift.

The Cycle of System Pallets is Fully Automatic

The raw materials are stored in big bags, which are lifted onto plastic system pallets with base dimensions of 1,000 x 1,200 mm along with a wooden pallet during storage. The provision and the entire cycle of the system pallets are fully automated via the conveyor system. Its layout was designed during the engineering phase in collaboration between Kardex Mlog and BASF according to the exact requirements. Thus, only clean and precise system pallets are transported throughout the Kardex MTower and the conveyor technology. “This ensures reliable operation and allows for flexible use of the different load carriers, which vary significantly in quality and standards,” says Marco Burkhart, Engineer, BASF SE.

The delivered raw materials are placed onto the provided system pallet by a forklift, which is then automatically transported away via the conveyor technology. During this process, the load units undergo a profile check, weight check, and an automatic scanner captures the item data.

The replenishment warehouses are managed by the Kardex Control Center developed by Kardex Mlog, featuring warehouse management Kardex WMS, system visualization Kardex MVisu, and material flow control Kardex MFlow. At the transfer point to the Kardex MTower, the warehouse management system determines the appropriate storage location and subsequently issues the storage order. Up to 40 pallets per hour can be stored in this manner.

At a height of about 19 m, there is a work platform with two removal stations and a collection point for packaging materials. Upon request from the operator, the big bags are removed. They are then manually unpacked, cleaned, and lifted off the pallet by crane and handed over to production.

Pallets are Automatically Stacked

Subsequently, the load carriers are transported to an empty pallet collector, where they are separated from the system pallet and collected. All pallets are automatically stacked and buffered in the Kardex MTower until they are needed at the incoming goods area or requested system-technically. The conveyor technology, also supplied by Kardex Mlog, includes 44 drive modules per system such as chain conveyors, roller conveyors, scissor lift tables, and corner turners with lift tables. Additionally, the delivery included 300 system pallets, a semi-stationary rack sprinkler system, a smoke suction alarm system (RAS), four high-speed and fire protection doors, as well as two manual racks on the ground floor with a total of 32 pallet spaces.

Photo: © BASF