Kardex Mlog BASF two identical buffer storage systems, "Mtower" type walking beam storage systems, including WMS to connect goods receiving and production. The two raw material replenishment warehouses offer space for 272 special load carriers weighing up to 1350 kg and operate 24/7.
TheMtower walking beam storage system, developed by Kardex Mlog, was specifically designed for narrow and high warehouses. The principle is based on a vertically guided walking beam on which a distribution carriage moves. This automated pallet storage system operates faster and more efficiently than other storage concepts based on stackercranes.
With the two new raw material storage facilities, BASF is decoupling external deliveries from production supply. The two identical Kardex MTower systems are located in adjacent buildings and enable the automated raw material supply for one plant. "The Kardex MTower was particularly appealing due to its extremely small footprint and variable height, which allows us to make optimal use of the existing buildings," explains BASF engineer Aaron Werner. The 24.7-meter-high storage units are connected to two building floors via conveyor systems, eliminating the need for an additional elevator.
The raw materials are contained in big bags, which, along with their wooden pallets, are lifted onto plastic system pallets with base dimensions of 1000 x 1200 mm during storage. The provision and complete circulation of the system pallets is fully automated via the conveyor system. Its layout was jointly designed by Kardex Mlog and BASF during the engineering phase, precisely according to the requirements. This ensures that only clean and perfectly fitting system pallets are transported throughout the entire Kardex MTower and the conveyor system. "This ensures reliable operation and enables the flexible use of the various load carriers, which sometimes differ significantly in quality and standards," says BASF engineer Marco Burkhart.
The delivered raw materials are placed onto the provided system pallet by a forklift, which is then transported away fully automatically via the conveyor system. During this process, the loading units undergo a profile check, weight check, and an automatic scanner records the item data.
The replenishment warehouses are managed by Kardex Mlog's own Control Center, which includes warehouse management, system visualization, and material flow control. At the transfer point to the MTower, the warehouse management system determines the appropriate storage location and then issues the putaway order. Up to 40 pallets per hour are put away in this way.
Photos: BASF SE
At a height of approximately 19 meters, there is a work platform with two unloading stations and a collection point for packaging materials. Upon request, the worker retrieves the big bags. They are then manually unpacked, cleaned, lifted from the pallet by crane, and transferred to production.
The load carriers are then transported to an empty pallet collector, separated from the system pallet, and collected. All pallets are automatically stacked and buffered in the Kardex MTower until they are either needed in goods receiving or requested by the system.
The conveyor technology, also supplied by Kardex, comprises 44 drive modules per system, including chain conveyors, roller conveyors, scissor lift tables, and corner transfer units with lift tables. The scope of supply also included 300 system pallets, a semi-stationary rack sprinkler system, an aspirating smoke detection system (ASS), four high-speed doors and four fire doors, as well as two manual racks on the ground floor with a total of 32 pallet positions.
