Toyota Material Handling Realizes High-Bay Warehouse for TDDK

The TD Deutsche Klimakompressor GmbH (TDDK) is expanding its storage capacities with Toyota Material Handling Germany (TMHDE) and its sister company viastore: To manage the planned production boost, a fully automated high-bay warehouse is being built as part of a comprehensive expansion project, elevating the logistics processes at the headquarters in Bernsdorf (Saxony) to a new level of efficiency.

(Isernhagen/Bernsdorf) Founded in 1998, TDDK develops innovative climate compressors for leading automotive manufacturers and has established itself as a key player in the automotive industry over two decades. As a joint venture of Toyota Industries Corporation (TICO) and DENSO Corporation, the company combines Japanese cutting-edge technology with German engineering expertise. Since 2000, TDDK has been producing at the Bernsdorf site with around 950 employees, supplying international brand manufacturers such as Daimler, BMW, VW, Toyota, Nissan, Ford, and Fiat.

In September 2022, the gradual transition from mechanical compressors powered by the combustion engine’s V-belt to electrically operated models was announced. This aims to increase the annual production capacity from six to eight million units. To manage this production boost, the company is expanding the existing factory area from 73,000 square meters by an additional 20,000 square meters.

Automated High-Bay Warehouse for Increased Capacity

The groundbreaking for the already sixth construction phase took place on June 16, 2023. The new, fully automated high-bay warehouse, implemented by Toyota Material Handling Germany in collaboration with the sister company viastore SYSTEMS, forms a central element. With an area of 74 by 40 meters and a height of 17 meters, it will span all three floors of the new building section and offer a storage capacity of a total of 13,000 pallet spaces.

The goal of the project is to optimize storage processes, reduce operating costs, and provide a modern intralogistical foundation for the expanded production capacities. The long-standing successful partnership between TDDK and Toyota Material Handling Germany provided the best arguments to rely on the experience and solution expertise of the leading intralogistics total solution provider for this major project.

“Automated systems from Toyota Material Handling are among the most advanced solutions for companies looking to elevate their logistics processes to a new level,” says André Eißler, Head of Production Engineering at TDDK.

Model Example for Integrated Logistics Solutions

By combining state-of-the-art technologies and seamless system integration, customers receive tailored total solutions from Toyota from a single source. Since 2018, driverless transport systems from Toyota Material Handling (AGF) have been in use at TDDK in conjunction with Toyota shelving systems. Over time, the number of vehicles and installations, as well as the scope of responsibilities for relevant material transports, has steadily increased. The leading Toyota software T-One and the latest loading technology have been integrated.

TDDK also benefits from a complete package that is optimally tailored to its own requirements: The complete shelving technology, including the pre-zone and Rail Guided Vehicles (RGVs), is supplied by TMHDE. The delivery of storage and retrieval systems, service, and technical support is provided by the sister company viastore, which is part of the Toyota Automated Logistics Group (TALG).

“As a total solution provider, we can deliver TDDK a perfectly coordinated complete package for expanding its storage capacities,” says Martina Möller, Head of Sales, Logistics Solutions & Digitalization at TMHDE.

The Stuttgart automation expert complements the service portfolio of Toyota Material Handling and ensures maximum efficiency and reliability in operations. “For more than 50 years, we have been planning, realizing, and modernizing automatic storage and material flow systems. We are now pleased that our experience plays a central role for TDDK,” explains viastore CEO Thomas Hibinger.

A Strong Foundation for the Future

The warehouse has already been constructed, so the shelving technology and storage and retrieval systems are currently being installed. The full commissioning of the new high-bay warehouse is planned for early 2025. TDDK is investing around 90 million euros in the structural expansion as well as in the machines and systems to future-proof production and storage for the coming years.

In the course of implementing the new high-bay warehouse, Toyota Material Handling will redesign and reliably fulfill the newly created goods flows through the use of the already proven and existing Automated Guided Forklifts (AGF).

Long-Term Growth and Technological Innovation

With the expansion of production capacities and the implementation of the fully automated high-bay warehouse, TDDK is focusing on long-term growth and technological innovation. It is also clear that the close collaboration with Toyota Material Handling Germany and viastore ensures that TDDK remains efficient and competitive in the future – thus taking another important step towards climate-friendly automobile production.

Photo: © Toyota Material Handling