Automation, as mentioned, doesn't have to be complicated. Even simple, repetitive logistical processes can be carried out automatically with high-lift pallet trucks like the EXV iGo. Forklift manufacturer Still successfully implemented this at DP-Supply, a subsidiary of Deutsche Milchkontor DMK.

At the production site in Beesten, Lower Saxony, the automated high-lift pallet truck receives a transport order – triggered by sensors in the conveyor system – upon the arrival of a pallet containing spray-dried powder products. The practical advantage: As a stand-alone solution, Still's plug-and-play system requires no complex installation or complicated control and does not necessarily need to be integrated into a higher-level ERP system. Route changes can also be implemented quickly and easily.

Triggered by sensors

With well-known brands such as Milram, Oldenburger, and Humana Babyfood, the DMK Group, Germany's largest dairy cooperative, processes around 5.5 billion kg of milk annually. Within the group, DP-Supply in Beesten primarily produces fat powder products, creamers, dairics, foamers, batics, nutrilics, as well as skimmed milk powder and contract drying products for select partners. These products are innovatively developed and manufactured to meet the requirements of the processing industry and are used in baked goods, soups and sauces, savory dishes, ice cream and desserts, as well as nutritional supplements and baby food.

All photos: G. Knehr

Stephan Runge, Head of Production at DP-Supply: “ With our experience in the production of spray-dried emulsions, we now operate worldwide for the food industry. To also meet the requirements for our new product groups Nutrilics and Babyfood, we installed an additional drying tower in 2019, where the sprayed emulsions dry at the top as they descend, using state-of-the-art spray technology. ”

Perfect entry point

Today, a wide variety of emulsions and formulations are sprayed and dried at the Beesten site and then exported in large quantities as far afield as the United Arab Emirates and West Africa. Runge: " Ultimately, we produce around 50,000 tons of finished products annually in various packaging options, from small bags to big bags. Due to the increased production volume running 24/7, we ultimately had to automate simple, repetitive transport processes. The driverless iGo easy provided us with the perfect solution. "

A lot of hot air at the drying tower

The smart automation solution Still iGo easy does not need to be integrated into DP-Supply's ERP system. Triggered by sensors and other signals, it can operate independently. Complex installations with costly interface programming are simply eliminated. The application has been designed for intuitive operation and requires no in-depth technical knowledge.

Simple implementation

During the go-live phase, specially trained service technicians installed the reflectors for laser navigation and entered the AGV parameters for the route and handover points using the simple and intuitive software in just two weeks. Should any changes to the route or adjustments to the software parameters be necessary later, the straightforward automation provides flexibility.

“ Thanks to its particularly simple and quick commissioning via the intuitive user interface, the plug-and-play solution offers us the perfect option for automating individual logistical transport processes with just one AGV. We can flexibly respond to further production increases with additional AGVs ” said the production manager. Reflectors for laser navigation can be quickly installed within the warehouse environment.

 Ride order via WLAN

The AGV transport order is issued in two stages. As soon as a pallet arrives at the conveyor transfer point or is wrapped at the stretch wrapper, I/O signals are triggered by a sensor and transmitted to the vehicle via WLAN as a transport order. Once initiated, transports are carried out continuously, 24/7, to the stretch wrapper upon arrival of the pallets from production and from there to the seven floor storage locations in the block storage area.

Lemke: “ According to a statistical capacity estimate, around ten transports per hour can be carried out. The overall availability of our system, according to current VDI guidelines, is already at 98 percent. ” The EXV iGo navigates using the triangulation method, employing a continuous laser scan of its surroundings. Reflectors are positioned at relevant points, their locations calculated along the routes using the user-friendly commissioning software and easily adjustable as needed.

10 transports per hour

The production manager is convinced of this type of navigation: " As soon as at least three reflectors are detected, the current position is calculated based on the distance and angle to each reflector " Stefan Schuster, service technician in Bremen, adds: " After installing the reflectors, we create navigation maps for the AGV using triangulation. This type of navigation is very precise. To reduce installation costs, we can also navigate using the warehouse's contours " Furthermore, routes and travel paths can be quickly modified graphically using drag-and-drop with the Still software.

Gerd Knehr

www.still.de