Toyota Material Handling and Viastore are helping air conditioning compressor manufacturer TDDK switch from belt-driven compressors at Daimler, BMW, VW, Toyota, Nissan, Ford and Fiat to electrically driven models by expanding a fully automated high-bay warehouse.
Founded in 1998, TDDK has developed into an established player in the automotive industry over the past two decades. As a joint venture between Toyota Industries Corporation (TICO) and DENSO Corporation, the company combines cutting-edge Japanese technology with German engineering expertise. Production has taken place at the Bernsdorf site since 2000, employing approximately 950 people.
In September 2022, the gradual switch from mechanical compressors driven by the combustion engine's V-belt to electrically powered models was announced. This is expected to increase annual production capacity from 6 to 8 million units. To handle this production surge, the company is expanding its existing factory area of 73,000 square meters by 20,000 square meters.
The groundbreaking ceremony for the sixth construction phase took place on June 16, 2023. A key element of this phase is the new, fully automated high-bay warehouse, implemented by Toyota Material Handling Germany in collaboration with its sister company Viastore Systems. Measuring 74 x 40 meters and 17 meters high, it will extend across all three floors of the new building section and offer a total storage capacity of 13,000 pallet spaces.
Since 2018, Toyota Material Handling (AGF) automated guided vehicles (AGVs) have been in use at TDDK in conjunction with Toyota racking systems. Over time, the number of vehicles and installations, as well as the level of responsibility for relevant material transport, have steadily increased. The leading Toyota T-One software and state-of-the-art loading technology have been integrated.
TDDK also benefits from a comprehensive package optimally tailored to its specific requirements: The complete racking system, including the pre-zone and rail-guided vehicles (RGVs), is supplied by TMHDE. The delivery of the storage and retrieval machines, service, and technical support are provided by its sister company Viastore, which belongs to the Toyota Automated Logistics Group (TALG).
Fig.: TMHDE
“For more than 50 years, we have been planning, implementing, and modernizing automated storage and material flow systems. Now we are delighted that our experience plays a central role for TDDK,” explains Viastore CEO Thomas Hibinger.
The warehouse building is already constructed, and the racking system and storage and retrieval machines are currently being installed. Full commissioning of the new high-bay warehouse is planned for early 2025. In total, TDDK is investing around €90 million in the building expansion as well as in the machinery and equipment to ensure future-proof production and warehousing for years to come.
As part of the implementation of the new high-bay warehouse, Toyota Material Handling is redesigning the newly created material flows through the use of the already proven and existing Automated Guided Forklifts (AGF).
Compressor technology
The TDDK compressors in the refrigerant circuits of passenger car air conditioning systems were the world's first to feature a so-called swashplate, enabling variable displacement. This allows the compression, and therefore the cooling capacity of the air conditioning system, to be controlled according to demand. Variable displacement compressors regulate the amount of refrigerant discharged by changing the angle of the rotating swashplate. This stepless control, which is tailored to engine and driving conditions, not only improves driving comfort but also helps reduce the vehicle's environmental impact by lowering the compressor's energy consumption.
