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The Gerolsteiner Brunnen GmbH & Co. KG has announced the construction of a new compact pallet warehouse at its headquarters in Gerolstein. This warehouse will be equipped with a 2D shuttle system designed for both the storage and distribution of finished goods. The project will be realized by Körber AG, which will be responsible for the turnkey implementation of the entire system as the general contractor. This includes the shuttle warehouse, pallet conveyor technology, and the connection to automated truck loading facilities. Additionally, the control and optimization of the system will be managed through SAP EWM.
Efficient Storage and Loading
The new warehouse will feature 15,800 pallet storage spaces arranged in channels, capable of accommodating up to 11 pallets. This structure allows for inbound and outbound storage from both sides. In the first phase of the project, 16 ATLAS pallet shuttles and four lifts from partner Movu will be deployed. This technology enables the storage of up to 90 pallets per hour and the retrieval of up to 190 pallets per hour. With increasing demands, throughput can be increased to 180 inbound and 290 outbound operations per hour by integrating additional shuttle vehicles and lifts. The entire facility is designed to be redundant and resilient, allowing individual vehicles or lifts to take over the tasks of others when needed.
Integration of SAP EWM
Körber will implement the essential parts of the business logic for controlling the warehouse directly in SAP EWM. This system will manage the inventory of the 2D shuttle warehouse with precise positioning and control the inbound and outbound strategies. Additionally, SAP EWM will optimize shuttle roaming and lifts. This architecture aims to ensure high transparency and efficiency while providing organizational relief for future optimizations. Changes can be made through a single system and one IT provider, which is advantageous for the client.
Another aspect of the SAP EWM functionality is the sequencing of pallets to enable optimized outbound and transport logistics to retail. Ingo Windshügel, Senior Vice President at Körber Supply Chain Consulting, emphasizes: “The seamless, central orchestration of all essential processes through Extended Warehouse Management and the powerful, redundant shuttle warehouse ensures maximum operational reliability with high, continuously scalable performance.” The commissioning of the new warehouse, including the optimization phase, is planned for the first half of 2027, which is less than a year after the installation of the shelves.
Sustainable Investments
Harald Jakoby, Head of Technical Planning at Gerolsteiner, highlights that the company, as a market leader in branded mineral water, is strategically investing in its future viability. A powerful logistics system that grows with the company’s demands is central to this effort. The high space and energy efficiency of the new shuttle warehouse contributes to the company’s sustainability strategy, while the intelligent networking of all processes through SAP EWM increases efficiency and reduces loading and unloading times at the ramp.
