f+h Intralogistics 2/2016

Intralogistics 

Trade magazine for material flow and material management 

INTERNATIONAL 

EDITION 

2 

May 2016 

LOGISTICS IT 

MANAGE & SERVICE 

MOVE & LIFT 

STORE & LOAD 

Supplement for international Supply Chain Management 

CeMAT – be inspired by new 

intralogistics solutions 

EMPACK/LABEL & PRINT 

Unusual cranedesign for restricted 

installation situation 

Augmented reality offers new 

possibilities for maintenance work 

Managing complexity 

with WMS 

www.fh-intralogistics.com in cooperation with 

Materials Handling 

and Intralogistics

Are li-ion batteries a 

fire hazard? 

In the meantime, nearly all manufacturers of industrial trucks are 

selling their warehouse technology devices with lithium ion batteries, 

even some forklifts are already available with these comparably new 

energy storage systems. In everyday practice, they offer invaluable 

advantages as they are not subject to the typical limitations of a 

standard lead-acid battery. Li-ion batteries can be charged very 

quickly, so that batteries no longer need to be changed even during 

multiple-shift operation. They also have a significantly higher volumetric 

capacity, increased charging energy efficiency and a longer service 

life expectancy. In addition, they are also maintenance-free. Overall, 

this all sounds very positive. 

If lithium batteries are 

used correctly, they do not 

pose a risk 

However, there are also some critics 

who believe that the new technology 

does pose some risks. These are 

certainly justified, as lithium is a 

highly reactive alkali metal. The 

softest of all solid elements, it even 

reacts with water and if touched it will cause chemical and physical 

burns due to skin moisture levels. These characteristics mean that a fire 

of a lithium battery cannot be extinguished with water. 

Other sectors have already hit the headlines for using this type of 

battery. The Dreamliner aircraft model from Boeing was grounded on a 

global scale for three months due to problems with the li-ion batteries. 

The media also reported about electric vehicles that caught fire 

following an accident. Are the new batteries a fire hazard? 

The German Environment Agency (UBA) has issued a general statement 

about lithium batteries and gives the all-clear as long as batteries 

are used and stored correctly. If handled correctly they can be deemed 

to be safe. However, it should be noted that if lithium-ion batteries are 

overcharged or totally discharged, they can 

react in a highly sensitive way. External 

influences, such as mechanical 

damage or a heat supply, can cause 

the battery to overheat which can 

subsequently cause a fire or an 

explosion. This is why each battery 

system must always include an 

intelligent electronic control system. 

Ultimately, manufacturers are required 

to design the overall system in 

such a way that the risk of this occurring 

is excluded. 

Holger Seybold 

(Editor-in-chief) 

EDITORIAL 

STORAGE. 

PRODUCTS. 

FLOW. 

In the world of logistics everything 

needs to keep moving. Whether 

automatically or manually, the seamless 

transport of goods; receiving, 

storage, or retrieval, is the key to 

excellent logistics. We‘ve designed our 

containers exactly with this in mind. 

Our containers are versatile and can 

be used in a number of different storage 

and handling systems. They work 

at every stage of the logistics chain so 

that everything runs like a clockwork. 

www.bekuplast.com 

Visit us at the 

CeMAT! 

31.05.–03.06.2016 

Hall 13 · Stand E11 

Industriestraße 1 · 49824 ·Ringe ·Germany 

Tel. +49 5944 9333-0 ·info@bekuplast.com

News and information from the 

entire world of intralogistics 

Retrofit without any production 

losses 

Yale donates the 400,000th produced 

truck to international charity 



Larsson: “Supply chain risk can hit 

in unexpected places” 

like us on facebook 

Study examines cost optimization in 

the returns network 

COLUMNS 

INDUSTRIAL TRUCKS 

F+H DISTRIBUTION 

TABLE OF CONTENT 

Editorial 

Worldwide news 

Imprint 

CRANES & HOISTS 

Compact crane for Kurtz – Wire rope 

hoists travel between crane bridges 

AFTER-SALES SERVICE 

Beumer Group develops smart 

maintenance system for customer 

support 

WAREHOUSING 

Retrofit without any production 

losses 

Primed for further growth: 

Niemann+Frey expands logistics 

capacity with SSI Schaefer 

Yale donates the 400,000th 

produced truck to international 

charity 

SOFTWARE 

Consumer goods manufacturer relies 

on Jungheinrich WMS 

TRADE FAIR CEMAT 2016 

CeMAT 2016 – The focus will be 

automation and digitalization 

5 Innovations you definitely 

shouldn´t miss at CeMAT 2016 

Fairground map 

Guest commentary: Understanding 

risks, boosting resilience 

STEEL LOGISTICS 

Reversing roles 

LOGISTICS MANAGEMENT 

Cost optimization in the returns 

network 

AIRPORT LOGISTICS 

The ten most high capacity airports 

in Europe form part of the global 

production and supply chain 

BUSINESS AND ECONOMY 

Islamic Republic of Iran: Facts and 

figures 

Preview f+h Distribution 3/2016 

f+h Intralogistics 2/2016

Visit us! 

CeMAT, Hanover, Germany 

May 31 – June 3, 2016 

Hall 27, stand K38 

SOME THINK 

DELIVERY 

ERRORS ARE 

INEVITABLE. 

WE THINK 

DIFFERENT. 

Running an efficient distribution centre makes a big difference to profitability 

and customer satisfaction. That’s why many leading brands put sortation 

systems from BEUMER and Crisplant at the heart of their supply chain. 

Through operational insight and analysis, BEUMER Group is able to deliver 

complete automated material handling systems that fit seamlessly into 

your process. Offering exceptional speed, capacity and accuracy, our 

technology makes a difference to your customers, your brand and your 

bottom line. 

For more information, visit www.beumergroup.com

1 

2 

WORLDWIDE NEWS 


1 

New Innovation Center is first of its 

kind in Asia Pacific 

The logistics provider DHL launched its Asia Pacific 

Innovation Center (APIC) in Singapore, to offer a visionary 

view of the logistics world, and develop innovative solutions 

to meet evolving supply chain needs. The multi-million dollar 

facility is DHL’s first innovation center outside of Germany, 

and the first dedicated center for innovative logistics services 

in the Asia Pacific region. The center is located within the 

€104-million DHL Supply Chain Advanced Regional Center 

(ARC) building at Singapore’s Tampines LogisPark. 

www.dpdhl.com 

3 

2 

Terex Port Solutions received order 

from Egypt 

Terex Port Solutions (TPS) received an order for six dieselelectric 

Terex rubber-tyred gantry cranes (RTG) from 

Alexandria Container and Cargo Handling Co. (ACCHCO), 

Egypt. The machines will be operated in the Alexandria 

Container Terminal and the El-Dekheila Container Terminal 

of the country’s main port, Port of Alexandria. When the 

cranes are commissioned in November 2016, they will join the 

more than 20 Terex RTG’s already in operation in Egypt. 

www.terexportsolutions.com 

4 

3 

Shanghai SUS Environment orders 

Demag process cranes 

Terex Material Handling, Germany is to equip another refuse 

incineration plant in China with process cranes. The company 

received the order from Shanghai SUS Environment Co., Ltd. 

for three semi-automatic Demag process cranes for the refuse 

incineration plant in Yinzhou, a district of Ningbo. The cranes 

are to be used for storing materials, assembling the correct 

blend of fuel and for serving the furnace. 

www.demagcranes.com 

4 

Siemens expands handling system 

at Bangalore International Airport 

Siemens Postal, Parcel & Airport Logistics (SPPAL) headquartered 

in Constance, Germany, has received an order to expand 

the baggage handling system in the arrival area of Bangalore 

International Airport in India. The company helps the airport 

operator to expand its capacities and further improve 

passenger convenience of international passengers. In 2015, 

Bangalore registered record numbers of 18 million travelers, 

accounting for a traffic growth of more than 25 percent. 

www.siemens.com/logistics 


Compact crane for Kurtz – Wire rope 

hoists travel between crane bridges 

Mechanical engineering company Kurtz Ersa, Kreuzwertheim/ 

Germany, required a new crane to lift larger and heavier 

components into a new milling machine. It needed to lift 16 

instead of the previous 5 tones and to travel on the existing 

crane runway. The lifting height and restricted clearance 

above the crane bridge also played a part. Stahl- und Kranbau 

Oeder, one of Stahl Cranesystems’ partners, developed a 

customized low-headroom crane with an unusual design. 

MULTIMEDIA CONTENT 

Learn more about the achievement 

spectrum of the enterprise 

CRANES & HOISTS 

Other impressions about the introduced 

project

Kurtz Ersa produces particle foam and casting machinery at its 

plant in Kreuzwertheim. The powerful machines are used all 

around the world – from low-pressure casting of engine blocks to 

pre-expanding and shape-moulding helmets and shoe soles. Kurtz 

Ersa relies on 235 years’ experience, well-trained personnel and 

modern machinery to produce these high-precision machines. At 

the beginning of August 2015, Kurtz Ersa commissioned a new travelling 

column milling machine that works to 0.017 mm accuracy 

over 10 m and with which larger and heavier components can now 

be processed. However neither the existing crane nor the crane runway 

were designed for the required lifting capacity of 16 t. Designing 

a new 16 t crane for the existing crane runway proved to be more 

difficult than expected and posed insoluble problems for some 

crane builders (Image 01). 

On the one hand, the limited clearance between crane runway 

and ceiling played a role, on the other the specifications for the lower 

edge of the load hook which could not collide with the milling 

machine’s spindle motor. Specialist for customized cranes, Stahlund 

Kranbau Oeder from Eckental in Franconia/South Germany, 

found the optimum solution: “The crucial point of the system was 

definitely the restricted installation situation and the existing crane 

runway which we could not reinforce,” Rudolf Lang remembers, an 

engineer from Stahl- und Kranbau Oeder, one of Stahl Cranesystems’ 

certified partners. Oeder supplied a customized crane with a 

headroom of only 943 mm from the upper edge of the wire rope 

hoist to the lower edge of the hook, that utilizes the lifting height up 

to 236 mm below the crane runway and still manages with the restricted 

space above the crane runway (Image 02). “The starting 

point was a standard Crane-Kit from Stahl Cranesystems with two 

8 tones wire rope hoists from the compact SH series – together with 

our motto: When space is tight, we’re the people you need,” Lang 

says. His solution based on a number of off-standard designs that 

would not be possible with a standard crane. “We had to devise a 

special construction for the crane bridge. On this crane, two SH wire 

rope hoists with modified crabs travel on rails mounted inside the 

bridge girders. Only this feature together with altering the distance 

between the bogie endcarriages made it possible to build such a 

compact crane”, Lang explains. 

The load is distributed onto coupled crane endcarriages with a total 

of 8 wheels so that the maximum load capacity of the crane runway 

is not exceeded. The load actually suspended from the hooks 

appears on the display of the radio remote control. The crane is also 

equipped with the safety features necessary for tandem operation. 

This can be activated via the remote control and enables lifting 

heavy and long workpieces safely. Norbert Jonas too, Kurtz Ersa’s 

production manager, is satisfied with the new crane. “You need creative 

engineers like Rudolf Lang and his colleagues to design a 

crane with these specifications – a remarkable achievement and a 

technically convincing crane. We’ll certainly get in touch with Stahlund 

Kranbau Oeder for future projects.” 

Photographs: Stahl Cranesystems 

www.stahlcranes.com 

01 Stahl- und Kranbau Oeder gained valuable 

centimetres with this design 

About Stahl Cranesystems 

Stahl Cranesystems GmbH, with head office in 

Künzelsau/Germany, has more than 140 years experience 

in crane construction. The manufacturer offers a full 

range of crane technology and crane components, 

including chain and rope hoists, winches, and light and 

small crane systems, as well as drive and control 

solutions. It is a world leader in explosion protected 

crane technology. Indeed, Stahl CraneSystems developed 

the first components for such applications as far back as 

1926, thus contributing to today’s industrial standards. 

The company manufactures its products at the Künzelsau 

plant, but has 9 foreign subsidiaries. It has more than 

700 employees worldwide. 

02 The compact wire rope hoists travel on a customised crab 

between the box girders 


Beumer Group develops smart 

maintenance system for 

customer support 

Augmented reality offers interesting possibilities and 

potentials, e. g. for maintenance work on intralogistic 

systems: a head-mounted minicomputer could display 

all necessary information to the service employee. This 

would simplify their work, hands-free. The Beumer 

Group development department places a high priority 

on this topic. 

Companies must repair their machines and systems quickly to 

avoid costly downtimes. This is becoming a more difficult task as 

systems are becoming increasingly complex, requiring highly qualified 

service technicians. Even the most skilled technicians sometimes 

have to read through heavy manuals, open up drawings or 

struggle with outdated plans. This costs valuable time, and should 

be so much easier in the digital age. Tablets, smartphones and 

smartwatches have become indispensable in our private lives. Even 

smartglasses are increasingly finding their way into our lives. A 

tourist strolling through Paris, sits down at the Eiffel tower, puts on 

his glasses and gets all the information he wants, according to his 

location and true to scale: How tall is the building? What are the 

opening hours? How did these scene look like 100 years ago? “We 

take up this technological trend, to complement reality with digital 

information,” says Dr. Andreas Werner, head of the research and development 

department with Beumer Group. “This app for smart 

maintenance will help facilitate maintenance work on intralogistic 

systems for Beumer Customer Support employees.” 

App facilitates maintenance 

Through AutoID characteristics on the logistic element, e. g. a conveyor, 

and the smart maintenance app, information on this element 

can be displayed, such as maintenance instructions or pin assignments. 

The service employee focuses on the object with his mobile 

device. The required data is displayed on the live image of the camera 

of the device. “The technician looks at the defective part and can 

immediately call up every related manuals or goods in stock,” explains 

Werner. 

Every process step is displayed. In the event of very complex processes, 

he can call a colleague by using the smartglasses and solve the 

problem together via live stream. Measured values could be recorded 

at the same time and transferred to the back-end system in real time. 

Video recordings and photos can document whether an order was 

carried out correctly and in compliance with the safety regulations. 




AFTER-SALES SERVICE 


Smartglasses (Image) are also very easy to use and their interfaces 

are standardized. Their availability however is still too low for industrial 

applications. As with smartwatches, the user requires additional 

devices. Smartglasses have many operating advantages, but they are 

still not developed enough to make an industrial use possible. 

Smart maintenance at Singapore airport 

“Tablets are already used at several airports that operate baggage 

handling systems from Beumer Group,” describes Werner. “This 

includes Singapore Changi Airport. As one of the main hubs for 

Southeast Asia, this airport is known to be very progressive and 

passenger-friendly.” 

Smart glasses are easy to use and their interfaces are standardized 

− however, the user needs additional equipment 

Smartglasses, tablet or mobile phone? 

“When implementing these wearable computer systems into 

intralogistics, you have to consider aspects like information security, 

ergonomic user interfaces and suitable IT structures,” explains 

Werner. 

The goal is to ensure a sustainable added value for companies 

and customers. But which mobile end device is the most efficient? 

The app can be used on smartphones and tablets for example. 

They offer the advantage of a high computing capacity. This allows 

you to process the large amount of data that is required for service 

tasks. Their interfaces are standardized and always have direct 

access to the Internet. Their handling is intuitive and easy. One big 

advantage: these devices are accepted technologies at the 

workplace because they are already indispensable in our private 

lives. Smartwatches, however, have a low computing capacity, their 

interfaces are sometimes specific to the manufacturer and the user 

requires additional devices. 

About Beumer 

The Beumer Group is an international leader in the 

manufacture of intralogistics systems for conveying, 

loading, palletizing, packaging, sortation and distribution 

technology. Together with Crisplant a/s and Enexco 

Teknologies India Limited, the Beumer Group employs 

4,000 people worldwide, and achieves an annual 

turnover of about 680 million EUR. With its subsidiaries 

and sales agencies, the Beumer Group serves customers 

around the globe, across a wide range of industries. 

With an app for smart 

maintenance on mobile 

end devices, our customer 

support technicians can quickly 

access all important data 

Dr. Andreas Werner, head of the research 

and development department with 

Beumer Group 

The baggage handling system was developed and integrated by 

Beumer Group. The company is exclusively responsible for ensuring 

trouble-free operation, optimum maintenance and therefore 

the long-term coordination of the baggage handling systems. This is 

why 121 employees take care of customer support. They provide 

24/7 operation at the baggage control rooms and necessary preventive 

maintenance to ensure continuous system availability and best 

performance. “The maintenance personnel can use the tablets to 

connect to individual system control components to check for 

example statuses or carry out modifications,” says Werner. 

Beumer Group employees can scan barcodes from components 

and look into further data, such as maintenance protocols, using 

the integrated camera. Maintenance and repairs are carried out a 

lot faster, and system standstills are reduced. This ensures reliable 

operation and reduces costs. 

Developers are currently carrying out an innovation study with 

the smartglasses at the airport. The employees receive information 

on the system layout in 2D via their device, the error history, or 

device-specific information, and gets VoIP access to customer support. 

They can access operating and maintenance instructions easily 

and quickly. All of the information necessary for troubleshooting 

the system is available. The device can also be connected to the 

smartphone via Bluetooth. 

Photographs: Beumer 

www.beumer.com 


Retrofit without any production losses 

WAREHOUSING 

As the service life increases, the availability of 

machines and systems is reduced due to wear and a 

lack of replacement parts. At the same technology is 

progressing and customer requirements are 

continuously increasing, so that the necessity to 

modernize electric and automation components 

becomes inevitable at some point. 

About Heitec 

Heitec is known for industrial competence in 

automation and electronics and offers solutions, 

products and services in the fields of software, 

mechanics and electronics. More than 2,000 customers 

increase their productivity and optimize their products 

with the help of Heitec’s state-of-the-art, reliable and 

economic system solutions. A work force of over 1,000 

employees at numerous sites worldwide provides 

high-quality industry skills close to the customer. 

Vacuumschmelze (VAC) GmbH & Co. KG based in Hanau, Germany, 

develops, produces and sells special magnetic materials 

and refined products derived from them. The range of products includes 

half-finished products and parts with magnetic and physical 

properties, inductive electronic components, as well as magnets 

and magnetic systems, which, amongst other things, are used in 

medical technology, and the automotive and aviation industries. 

The half-finished products and raw materials used for production 

are temporarily stored in the manufacturer’s high-bay warehouse 

constructed in 1980. The warehouse has a capacity of 3,800 storage 

positions spread across eight rack rows. Four racking storage and 

retrieval vehicles store and retrieve the pallets that vary in size and 

can weigh up to 2.5 tones. 

To date, all of the storage and retrieval operations were controlled 

via a Simatic S5-135U programmable logic control unit 

with a Coros visualization system. “Our problem was that a lot of 

the hardware components being used had already been discontinued 

in the 1990s and a continuous supply of replacement parts was 

no longer guaranteed,” explains Joachim Koch, Manager of Warehousing/Transportation 

at VAC. “In addition to it being difficult to 

obtain replacement parts, there were hardly any specialists who 

could master the old technology. This made us come to the decision 

to migrate the system.” 

The aim was to update the existing system to the state-of-the-art 

by replacing old components and adding current technological developments. 

The automation and drive technology were replaced as 


01 Storage and retrieval operations continue without any 

interruptions despite the ongoing retrofit work 

part of the modernization project, whereby the energy costs could 

be significantly reduced. 

Open heart surgery 

Before calling for tenders for the retrofit project, the automation 

specialist, Heitec, based in Erlangen, Germany, analyzed the modernization 

requirements and created a performance specification 

that included all of the key points and was discussed with all of the 

parties involved, such as the managers, operators and maintenance 

technicians. During this process, it was determined that the design 

of the operating functions on the control panels should not be 

changed significantly thus making it easier for the system operators 

to switch to the new system. The safety technology also needed to be 

updated in accordance with the latest state of the art. At the same 

time, the storage and retrieval operations (Image 01) could not be 

affected during the conversion due to ongoing production. 

To reduce project risks, Heitec developed the actual commissioning 

concept on a virtual model. The procedure was implemented as 

follows: To complete a retrofit, the specialists analyze the system on 

site, record the characteristics, generate a sketch of the system 

geometry and use this to create a virtual model on the computer 

(Image 02). The control software is tested and optimized on these 

models and placed into virtual operation before each of the retrofitting 

stages. The models provide significant functional data about a 

high-bay warehouse in real time so that the new control software 

can be tested without blocking the real system. The commissioner 

uses the computer to execute exactly what he needs to do when 

commissioning the actual machine. 

With the help of the concept, the old and new system could be operated 

in parallel and the retrofitting work could be completed in 

stages. The new drive systems and control units for the racking storage 

and retrieval vehicles were preassembled and installed on 

mounting plates to ensure they could be exchanged swiftly. During 

the retrofitting phase, the old central control system was coupled 

via a corresponding interface with the new control unit so that all of 

the old and new functionalities were guaranteed while the retrofit 

was being implemented. The central control system, that coordinates 

the storage and retrieval operations in all of the lanes, was 

only replaced once all of the racking storage and retrieval vehicles 

had been retrofitted. 

02 An animated model on the computer illustrates 

the functional data of the high-bay warehouse 


WAREHOUSING 

Optimizing processes 

We expect the retrofit 

to increase the availability 

of the system and to lower 

operating costs 

Joachim Koch, Manager of 

Warehousing / Transportation at 

Vacuumschmelze in Hanau 

03 Data collected using measuring light curtains is used to determine 

the type of storage required 

About PSI Technics 

Founded in 2005, PSI Technics specializes in developing 

and distributing innovative solutions for production and 

intralogistics. The company focuses on industrial 

positioning systems, industrial image processing, 

thermal protection enclosures for sensitive sensors, 

optimization, modernization and retrofitting, including 

motion analyses and virtual modeling. PSI Technics 

works on a global level with renowned partners such as 

Volkswagen, BMW, Bosch, Daimler, Boeing, SKF or AK 

Steel. 

The Simatic S7-317F programmable logic control units are used for 

the primary process controls and to operate the racking storage and 

retrieval vehicles. The system is operated via a WinCC client/server 

solution. The drive of the transport and lifting drives is operated via 

Simotics-1PH8 asynchronous motors controlled by Sinamics-S120 

frequency converters. Their active line modules generate a controlled 

intermediate circuit voltage and are regenerative. 

Profinet is the new bus system that connects the decentralized 

peripheral devices to the controllers. WLAN could, however, not be 

integrated into the design as a large number of strong permanent 

magnets are often stored in the warehouse. The data from the individual 

control units and subsystems is thus transmitted contactlessly 

by Profinet via DDLS data transmission units. 

The Aratec system from PSI Technics is used to position the racking 

storage and retrieval vehicles. The programmable logic control 

unit transmits the target stations and movement commands via 

Profinet to the positioning system, which has saved the corresponding 

coordinates and specifies the speed for the frequency converters 

via the target values. The absolute values of the laser distance 

measuring devices are imported via the SSI interface. 

The positioning system is able to automatically characterize and 

memorize the machine behavior. This means that the movement 

sequences of the machine can be controlled optimally regardless of 

the load and speed. The system is fitted with energy optimization 

software (FLP6000EOS) for the time-optimized movement processes 

between the driving- and lifting axis. The brake controls integrated 

in the frequency converters are released via the digital outputs of 

the positioning system. A movement analysis that was completed 

before and after the retrofit using Aratec-FLP6000MA software illustrated 

graphically that the handling of the racking storage and retrieval 

vehicles had significantly improved. 

Overshooting during the acceleration processes on the transport 

and lifting axis and the number of load changes when starting and 

stopping have been eliminated. This subsequently reduces the 

amount of mechanical wear and increases the service life. In addition, 

the positioning time for each trip was reduced by 4.5 s on the 

transport axis and by one second on the lifting axis. 

New functionalities make work easier 

As part of the modernization, the aim was to rework functions such 

as the contour checks, weighing and operational processes, and to 

update them to the latest state of the art. At the same time, the single 

channel, conventional safety technology was replaced with a multichannel 

wiring system on fail-safe PLC assemblies. 

During storage and retrieval operations, a distinction is made between 

seven different pallet types depending on the pallet feet, 

weight and dimensions. Measuring light curtains (Image 03) check 

the pallets and save their height dimensions while light barriers 

scan the pallet feet. The weight of the load carriers is determined 

with the help of Siwarex U weighing cells. The weight, height and 

pallet type parameters can then be used to determine the type of 

storage and compare it with the values specified by SAP. The printed 

DMC code then provides information about the storage location, 

material number and batch, unit quantity and volume. 

Access control is granted by muting the light arrays. The pallet is 

scanned by sensors to safely differentiate between the material flow 

and humans. “Before the modernization, an operator had to climb 

up three to four times a week because one of the pallets had become 

stuck. Manual operation also could not be reproduced as this also 

caused the system to crash. The new software ensures that the retrieval 

vehicle is positioned more directly and accurately. And the 

operator now only has to climb up once every six months,” explains 

Koch. 

Photographs: Heitec 

www.psi-technics.com 


Clear the ring at the CeMAT 

31. May–03. June 2016, Pavilion 33 and 34 

More endurance. More performance. 

16 hours with one single battery charge. 

Learn more now at: 

jungheinrich.com/2shifts

Primed for further growth: 

Niemann+Frey expands logistics 

capacity with SSI Schaefer 

WAREHOUSING 

At its logistics centre in Krefeld/Germany, motorcycle 

and scooter parts wholesaler Niemann+Frey places 

great emphasis on a flexible warehouse logistics, 

allowing same-day dispatch of over 50,000 different 

spare parts. When equipping the warehouse with racks 

and work stations as well as the recently installed 

conveying systems and two Logimats for automatic 

storage and picking of small parts, the company once 

again turned to complete service provider SSI Schaefer. 

Spring at last – and once again motorcycle and scooter enthusiasts 

are eagerly awaiting the start of the season. Motorcycles and 

scooters are being dusted down, ready for the much-anticipated 

first outing of the year. But very often the road to happiness goes via 

a workshop where the vehicle can be inspected, and repaired if necessary, 

by a professional. If the mechanic needs spare parts, he 

knows he can rely on Niemann+Frey, as this wholesaler stocks a 

range of over 150,000 different spare parts and accessories for motorcycles 

and scooters. It always has 50,000 of these in its warehouse 

and therefore guarantees a 97% delivery rate. If spare parts are ordered 

by 4 p.m., they are dispatched on the same day and delivered 

overnight throughout Germany and to many parts of Europe. Nearly 

80% of orders are now placed on the internet via the online shop. 

“The export business keeps us busy in the winter. But the summer 

months are very demanding for the people in logistics,” says Thomas 

Schild, Authorized Representative and Logistics Manager at 

Niemann+Frey, who admits: “I am constantly impressed by what 



Other impressions about the introduced 

project 

01 The automatic 

conveyor system 

connects the various 

picking stations on three 

levels with each other 

we achieve here on a daily basis. Over six tones of spare parts – right 

down to the smallest screw – are picked, packed and dispatched 

every day. At the same time, another six tones are received, recorded, 

stored and booked in so that they are ready for retailers as soon 

as possible. To achieve all this you need a top-quality team and 

flexible logistics.” Every day during the season the warehouse 

employees at Niemann+Frey pick around 750 orders, each averaging 

9.5 items, and prepare them for dispatch. 

In February 2010 Niemann+Frey moved into a new warehouse in 

Krefeld with a modern storage area of approximately 7,500 m². In 

collaboration with SSI Schaefer, the company created eight work 

stations in the 600 m² goods-in area, a pallet racking system with 

4,000 storage locations, a three-storey platform with longspan racking 

systems and 12,500 running metres of shelving, six packing stations, 

16 lines for shipping, 10 dock levellers and eight loading 

ramps. 

But with two-figure growth rates year on year and the addition of 

new articles all the time, by 2014 the warehouse was already in danger 

of reaching its capacity limits, causing Gerd Frey and Thomas 

Schild to consider possible expansion – including the option of 

building on the adjacent reserve area. However, an alternative logistics 

concept developed jointly with SSI Schaefer promised a more 

attractive solution from both the economic and the environmental 

perspective. The proposal was for partial automation of the ware- 

How far will we go in our pursuit of outstanding quality? There are not 

enough words in the dictionary to express this. Each project is different and 

unique. STAHL CraneSystems’ engineers rise to every challenge, even 

one that appears to be insoluble. All around the world, we work hand in hand 

with anetwork of 9subsidiaries and over 140partners. That’sthe Art of 

Engineering. That’sSTAHL CraneSystems.

02 Frontal view of the 

additonal three-storey 

floating platform 

WAREHOUSING 

house within the existing infrastructure, including incorporation 

and optimization of the current processes. Essentially, two Logimats 

would be installed for storage and picking of small parts, and a container 

and carton conveying system would be built to link goods-in 

with the various picking stations over three levels (Image 01). 

First steps in warehouse automation 

SSI Schaefer started work shortly after the contract was signed in 

October 2014, while the warehouse continued to operate. The first 

step was to dismantle parts of the platform system so that the Logimats 

could be installed side by side in the specified position. The fitters 

then erected the two automatic storage systems, which extended 

to just under the warehouse roof as they can be built to any specified 

height. The Logimat principle can be compared with an oversized, 

automatic drawer cabinet with two stacks of trays. A lift 

running between the two stacks of trays removes the individual 

trays from their allocated position and transports them to the pick 

face where the warehouse staff can remove the goods to be picked 

at an ergonomic height. In front of the two Logimats, Niemann+Frey 

has a picking station with ten container storage locations and putto-light 

displays. Immediately behind them, the conveying section 

runs towards the three other manual picking stations. 

Another three-storey floating platform was added to the existing 

three-storey platform system by building over the existing goods-in 

area, which was redesigned with new work station systems 

(Image 02). Part of the new platform is used as a conveyor branch 

with a buffer section for the individual picking levels. Installation of 

the conveying system, including a roller conveyor with belt conveyors 

to supply the platform, greatly reduced the distances walked by 

pickers and they no longer need to change level by walking up the 

stairs with containers or goods. This has made picking at the upper 

levels much more efficient, with faster access to the articles stored 

at those levels. 

“Niemann+Frey had very specific concepts and ideas with regard 

to expansion of its warehouse, which we then developed together. 

In particular, the order picking process using the Logimat, combined 

with put-to-light assignment and still using manual guidance 

of the container to the four picking stations via the conveying system, 

based on lists and simple identification information was new 

to us in this form,” explains Felix Lütkebomk, SSI Schaefer project 

About SSI Schaefer 

SSI Schaefer is the world’s leading supplier of 

warehousing and logistics systems. The services offered 

range from elaborating designs to equipping warehouses 

with products from the company’s own production and 

implementing comprehensive logistics projects as the 

general contractor. The grouping of competencies under 

the umbrella brand name of SSI Schaefer forms the basis 

of developing storage systems geared to market requirements 

and of finding holistic solutions in the field of 

intralogistics for a variety of industries. 


manager at the end of the implementation phase, which lasted approximately 

two-and-a-half months. 

For Niemann+Frey, on the other hand, the project was the first 

step towards automatic support for its internal storage, transport 

and picking processes. “We needed to create more space for our 

goods and the Logimat has enabled us to access significantly more 

articles from ground level using the goods-to-person principle, 

even when they are stored at higher levels. We have also increased 

our picking performance for the range of articles stored here because 

eliminating walking time and introducing parallel picking of 

ten orders at a time has made us much faster,” says Schild. 

Logimat – plenty of space within a very small area 

The Logimat storage lifts were installed in the existing platform system 

immediately behind the goods-in area and have space for 

12,000 different articles. They start to retrieve the correct tray of 

goods as soon as the picker has linked the first order with the first 

container by scanning the barcode. Picking starts when all ten containers 

have been assigned to an order. The employee always operates 

the two Logimats alternately by confirming each pick on the 

pick-to-light module. The software from SSI Schaefer is linked to the 

ERP system by an interface and controls the sequence of articles to 

be picked so that, wherever possible, it always retrieves a tray which 

contains several of the articles needed for the orders that are currently 

being picked. For easier picking, the LogiTilt function tilts the 

tray and the correct compartment is indicated by a laser pointer and 

on the stand-up display. 

The put-to-light display above the containers tells the picker 

where to place the article that has just been removed from the Logimat. 

Some articles also need to be labelled or packed separately. 

The light turns green to indicate that the last article in the order has 

been picked and the container can then be pushed onto the conveying 

section and moved to the transfer location for goods-out. If the 

container has to go to other picking warehouse zones, the employee 

attaches a clip to the container as an identifying mark for colleagues 

at the individual stations. 

Summing up, Schild explains: “Orders now move through the 

warehouse faster as the conveying system takes the container to 

the right picking warehouse zone and it takes less time to reach 

goods-out. As a result, utilization of the individual areas is much 

more consistent.” 

Photographs: SSI Schaefer 

www.ssi-schaefer.com 

Click to read 

previous issues. 

Inspiration is just 

one click away. 

YOU SHOULD NOT 

COMPARE APPLES 

AND ORANGES! 

Visit us: CeMAT! 

Hall 27 - Booth H58 

News about the following markets: 

www.laweco.de

Yale donates the 400,000th produced 

truck to international charity 

To celebrate production of the 400,000th truck at its 

plant in Northern Ireland, Yale Europe Materials 

Handling has made the largest single charitable 

donation in its history. As the specially manufactured 

truck rolled off the production line, employees at the 

Craigavon factory marked the milestone by handing it 

over to international charity Oxfam, for use at its 

distribution center in Bicester. 

The ceremonial presentation of the Yale Veracitor VX, which has 

been signed by all of the staff at the Craigavon factory, was made 

to Oxfam GB’s Finance Director Alison Hopkinson by Craigavon 

Plant Manager Jim Downey during an exclusive event on January 

19th before a specially invited audience of employees, suppliers, 

and dignitaries, including the Lord Mayor of Craigavon. Prior to the 

grand reveal, guests enjoyed factory tours of the plant, a series of 

presentations from senior members of the Yale team and a video 

showcasing the journey of the charity truck as it progressed along 

the production line (Image 01 and 02). 

Saving lives around the world 

Oxfam responds to emergencies around the world, for example saving 

lives by delivering the ability to source and store clean water for 

drinking and sanitation. Its Bicester depot currently operates with a 

20-year-old counterbalance 2.5 ton, LPG, 4-wheel truck which is in 

desperate need of replacing. The Yale Veracitor VX was selected as 

the truck of choice, because it offers high levels of productivity, ergonomics 

and dependability. 

01 There are more than 400 Signatures from proud Yale workers of 

Craigavon on the donated jubilee truck 

Iain Friar, Yale brand manager, said: “We are all incredibly proud 

that the 400,000th truck has been produced here in Craigavon, and 

we wanted to celebrate the contribution made by so many people in 

achieving that milestone. Yale is committed to our tagline ‘people, 

products and productivity’ and we firmly believe that it is our people 

who have put us where we are today. The 400,000th truck is the 

embodiment of the innovative approach and loyalty we receive 

from our Yale people. We wanted to choose a charity with the same 

ethos as Yale, an organization like ourselves that has people at its 

core. Not only is Oxfam internationally recognized for helping people 

in need, we felt that one of our forklift trucks would actually be 

of real benefit to its operation.” 

About Yale 

Yale Europe Materials Handling is a trading name of 

Nacco Materials Handling Limited, part of Nacco Materials 

Handling Group, Inc. (NMHG), a wholly owned 

subsidiary of Hyster-Yale Materials Handling, Inc. 

(NYSE:HY). Hyster-Yale Materials Handling, Inc. and its 

subsidiaries, headquartered in Cleveland, Ohio, employ 

approximately 5,500 people worldwide. 

FORKLIFT TRUCKS 


Discover how the jubilee truck was build 

including statements of Yale Managing 

Director Harry Sands 


Ergonomic discharging device enables 

higher throughput 

Automated tray storage system 

ensures just-in-sequence-production 

COLOMBIA 

Electric forklift power in the Turkish 

wood industry 

Gruchow: “Five reasons you should 

visit the CeMAT 2016 at Hanover” 

Motion, Drive and Automation 

www.mda-technologies.com 

SLOVAKIA 

in cooperation with 

www.ate-magazine.com 

Fluidtechnik 

Antriebstechnik 

in cooperation with 

April 2016 

AUSTRALIA BRASIL CHINA GERMANY 

INDIA ITALY RUSSIA TURKEY USA 

02 Rod Hogg (left), Logistics Manager of Oxfam, is happy to receive 

the keys and to replace their old forklift truck 

Hopkinson said: “This forklift truck will be used in our Bicester 

warehouse where we hold equipment to deploy at speed wherever 

in the world there is an emergency. The new truck will 

replace the 20-year-old model our logistics team currently use. So 

not only does this truck represent a real cost saving to Oxfam, it 

will help us come to the aid of people in desperate need more 

efficiently. Oxfam relies on the generosity of its supporters and we 

are so grateful and touched by the Yale team’s kind and thoughtful 

gift.” 

Tailored for operation purpose 

Behind the scenes planning for the charitable donation began 

many months ago, with the technical team from Yale asking Oxfam 

exactly what sort of truck would suit its needs in terms of capacity, 

capability and fuel type. By liaising with the logistics manager from 

Oxfam, UK territory manager for Yale, Andrew Hine, specified that 

the 400,000th truck should be a GDP/GLP20-30VX model, selected 

for its maneuverability, reach and ease of use. 

Oxfam’s Bicester warehouse handles a variety of load sizes and 

weights, which have been manually weighed on scales prior to dispatch 

via air freight around the world. Yale’s partners, Ravas have 

generously donated i-Forks for the 400k truck to save Oxfam precious 

time by automatically weighing the load when it is lifted. As 

Oxfam’s truck needs to be always ready to respond to emergencies, 

Yale’s UK dealer, Briggs Equipment, has offered to maintain and 

service the truck. This is another example of Yale working with its 

partners to tailor the solution to the client. 

The Veracitor VX offers innovative technology to reduce brake 

and tire wear, longer service intervals, and high engineering quality. 

Fuel efficiency is built in; the Yanmar 2.6L diesel engine consumes 

as little as 3.0 liters per hour, while the LPG engine range 

delivers new levels of performance. 

Photographs: Yale, f+h 

Targeting on global 

technology markets? 

INTERNATIONAL 

EDITION 


Trade magazine for material flow and material management 1 

March 2016 

www.fh-intralogistics.com in cooperation with Materials Handling 

and Intralogistics 

Reach international 

decision makers! 

www.fh-intralogistics.com 

www.mda-technologies.com 

www.ate-magazine.com 


Intelligent drives with 

endless applications 

It’s time for 

Hannover again 

Investigating the secret 

of rocky planets 

INTERNATIONAL 

EDITION 

2 

April 2016 

incl. Supplement 

COMPRESSED AIR NEWS 

Innovative solutions for 

reliable power transmission 

Hannover Messe 

Explore industrial 

technologies 

Colourful world 

Measurement in 

paint production 

INTERNATIONAL 

ONLINE EDITION 

2 

Web-based solution 

Fast and secure access to 

machines and plants 

Cloud automation 

How much do we 

need? 

Machine Vision 

No human errors 

anymore 

www.yale.com 

f+h Intralogistics 3/2015 21

Consumer goods manufacturer 

relies on Jungheinrich WMS 

DS Produkte, a consumer goods manufacturer, has 

complex requirements for its warehouse management 

system. By employing Jungheinrich WMS, the 

company benefits not only from the system’s 

optimized, transparent and secure processes in all 

intralogistics areas, but also from enhanced 

productivity and greater adaptability to changing 

circumstances. 

Our tour of the logistics center located in Gallin in the north-east 

of Germany is essentially an excursion through the facility’s 

omnipresent warehouse management system. In the words of “tour 

guide” Frank Müller, Head of Logistics Operations at DS Produkte: 

“As a result of expanded customer and order structures as well as 

our company’s growing sales, it became indispensable to invest in a 

WMS system that would seamlessly reflect our intralogistics processes. 

The previous warehouse management system from a different 

provider was no longer up-to-the-minute, since it only allowed 

us to manage high-rack warehouse inventories.” 

Complex requirements 

SOFTWARE 




DS Produkte originally ordered the WMS in a “light” version that included 

the most important standards. Twelve months after initial 

implementation, the other functions were added. The standard version 

of Jungheinrich WMS already includes extensive functions for 

warehouse modelling, equipment control and optimization of material 

flows as well as centralized master data administration. The 

standard version also offers a comprehensive reporting function 

that provides individually configurable analyses and as a result 

complete process transparency. In addition it features numerous 

standard interfaces which allow the user to hook the WMS system 

up to existing system environments, plus a number of different inventory 

options. 

Müller begins the tour in the WMS work preparation area, where 

staff members follow each process on their screens while issuing 

and managing orders. “We were looking for a WMS provider who 

was capable of meeting our highly complex customer and item-specific 

requirements,” says Müller. 

This complexity is due on the one hand to the many intralogistics 

areas which are connected with the logistic center’s WMS system 

(Image 01). This includes incoming goods, which takes in a daily 

total of 500 pallets’ worth of items, along with 

a 13 m high narrow aisle warehouse consisting 

of 32 aisles, each of them 37 m long, and 

17,000 pallet storage slots as well as cantilever 

shelves installed at the front of the high-rack 

warehouse and which are used as transfer stations. 

Added to this are the packing and loading 

areas, a wide aisle order picking warehouse 

and the outgoing goods area where a 

total of approximately 500 pallets and 5,500 

packed packages are handled daily. Apart 

from the 30,000 pallet storage slots inside the 


01 Staff members in the WMS work preparation area track all 

processes on their screens, while issuing and managing orders 

02 One solution consists of the packing areas, for which the 

manufacturer adapted and expanded the WMS packing functions 

logistics center, the WMS also manages 5,000 additional slots in outdoor 

storage. 

The high degree of complexity is also due to the operator’s broad 

range of tasks, for which special solutions were required. One solutions 

highlight consists of the packing areas where the WMS – 

equipped with adapted and expanded packing functions – receives 

customer-specific packing instructions and has the orders processed 

accordingly (Image 02). To demonstrate the diversity of 

these tasks Müller enters the B2C packing area. “This is where delivery 

slips, invoices and return labels are printed out and placed, often 

with flyers, in the packages along with the goods.” 

Comprehensive processing of returned orders 

DS Produkte moreover uses the WMS to control a bypass function at 

the narrow aisle warehouse, plus the one and two-stage order picking 

at the logistics center as well as returns processing which includes 

the reception, processing and return to stock of saleable 

goods. Apart from this Jungheinrich put the focus on accelerated 

processes. One example consists of order picking using finger scanners 

which enable staff members to hold a package with two hands 

and at the same time scan its barcode. A second example involves 

the cantilever racking, where the WMS interacts with RFID transponders 

to ensure 100 % accuracy, including both the transfer of 

the goods delivered by reach truck as well as their pickup via narrow 

aisle forklifts controlled by the warehouse navigation system. The 

use of the WMS system in combination with RFID transponders results 

in time savings of approximately 20 % in order processing. And 

the WMS also provides for easier and more efficient inventory management 

as well as substantially more reproducible and executable 

processes and a high degree of adaptability to new requirements. 

Among the most important Jungheinrich WMS modules employed 

by DS Produkte are the Client Module, Material Flow Computer, 

Production Order Module and BBD Management Module as 

well as the custom-developed Returns Module. A stacker control 

system operating via wireless communication was moreover implemented, 

one that guarantees a balanced utilization of the capacity 

of the Jungheinrich-delivered fleet of trucks, consisting of four narrow 

aisle stackers, eight reach trucks, nine tri-lateral forklifts, five 

sprinters and nine low platform side-seat trucks. 

Close cooperation 

A close cooperation has existed between DS Produkte and 

Jungheinrich since 1995, when the Stapelfeld-based consumer 

goods manufacturer began planning its logistics center in Gallin. 

DS Produkte placed a premium on a high degree of flexibility and 

performance capability, making the decision to invest in industrial 

trucks, rack systems and planning support from Jungheinrich. As 

Müller recalls, “Jungheinrich scored points primarily because it was 

a complete systems provider. What really convinced us was the coherent 

systems advice and practical experience they had accumulated 

by implementing a number of similar projects. We were also 

pleased that our requests in terms of system security and occupational 

health and safety were taken seriously.” 

Müller sounds equally satisfied with his company’s choice of a 

WMS system, reporting that Jungheinrich had “fully met” his company’s 

complex requirements: “The solution consisted of controlling 

the processes based on the order category. We see the results in 

optimized, for instance faster processes, a high degree of transparency 

in terms of the data and goods in all warehouse areas, a tangibly 

lower error rate and higher productivity. The latter allows us to 

process a substantially larger number of orders without needing to 

hire more personnel or spend more time.” 

DS Produkte also gives high scores that that package consisting of 

software, warehouse technology and industrial trucks all come from 

a single supplier, thus making any discussion of interface problems 

superfluous. The company also emphasizes the fine quality of service 

for all these areas, including useful advice and support in commissioning 

the various systems and the high availability of the 

WMS, which is in operation six days a week and up to now has never 

had a breakdown. 

Both companies are continuing their cooperation in joint workshops 

as a basis for possible necessary adaptations of the warehouse 

management system to changing circumstances. According to 

Müller: “New computer and WMS-relevant tasks have arisen, owing 

to the fact that our original planning assumed around 4,000 orders 

per day, but now we have up to 11,000. This jump in orders is due to 

an increase in B2C orders.” As the growth of DS Produkte appears to 

presage additional developments of this kind, the company can only 

benefit from the “future-proof” nature of Jungheinrich WMS. 

Photographs: Jungheinrich 

www.jungheinrich.com 

About Jungheinrich 

Jungheinrich is one of the world’s leading companies in 

the industrial truck, warehousing and material flow 

engineering sectors. As a manufacturing service and 

solution provider in the field of intralogistics, the 

company, based in Hamburg, Germany, supports its 

customers with a comprehensive product range that 

includes forklift trucks, shelving systems, services and 

consulting. The Jungheinrich share is traded on all 

German stock exchanges. 


CeMAT 2016 – The focus will be 

automation and digitalization 


The lead theme for CeMAT 2016 is “Smart Supply 

Chain Solutions”. That means, the foremost trade 

show for intralogistics and supply chain management 

– which runs from 31 May to 3 June in Hanover, 

Germany – will highlight the pivotal role of logistics in 

today’s increasingly digitized and integrated industrial 

value chains. 

C 

eMAT is where many of the solutions that will shape the future of 

intralogistics are first presented to a worldwide audience. In this 

year the focus will be automation and digitalization. “The impact of 

Industry 4.0 technologies on logistics will be the overarching theme 

at the upcoming CeMAT. Soon, all parts containers, racks, materials 

handling and transport systems and even the materials themselves 

will be intelligent. This will greatly increase the flexibility of logistics 

processes and companies’ ability to control and monitor them. 

Competitiveness in the logistics industry ultimately comes down to 

speed, precision, flexibility and availability. Digitalization will boost 

logistics companies’ performance across all of these critical success 

factors,” said Dr. Andreas Gruchow (Image 01), member of the 

Managing Board at Deutsche Messe, during the CeMAT Preview in 

Hanover. 

Solid growth projected for intralogistics 

technology 

The intralogistics industry is on a steady growth trajectory. Last year, 

manufacturers of intralogistics solutions in Germany alone 

produced 20.1 billion euros worth of equipment – up three percent 

on the previous year. Germany’s VDMA Materials Handling and 

Intralogistics Association forecasts similar growth for the current 

year. “These sorts of growth figures are underpinned by the positive 

development of Europe’s Common Market. The positive performance 

of some target industries around the world has also been 

instrumental in keeping manufacturers’ order books full. E-commerce 

and the automotive industry are key examples of this,” 

explained the association’s President, Sascha Schmel (Image 02). 


SYSTEMS. 

SOFTWARE. 

SERVICES. 

Intralogistics: viastore 

Visit us: 

Hannover · Germany 

31 May - 3 June 2016 

Hall 27, Stand B38 

info@viastore.com ·www.viastore.com

01 02 


New “Logistics IT” showcase 

Software is becoming an increasingly important part of the intralogistics 

market. In recognition of this, CeMAT’s organizers have created 

a new, dedicated display area for all the latest logistics software 

applications – the Logistics IT in Hall 27. “Smart IT solutions are 

fundamental to modern logistics. IT is now the number one driver 

and source of innovation in logistics. Developments like mobile 

Internet and the digital integration of all end-users into the production 

and supply chain are opening up new opportunities and giving 

rise to new business models,” remarked Gruchow. 

It is only fitting then, that SAP, the world’s leading enterprise software 

company, should be exhibiting at the fair. SAP and six partner 

companies will debut at the show with their latest industry solutions 

in the Logistics IT display area. Their pavilion will be themed 

“Integrated Logistics”. 

Another highlight of the new showcase will be the Logistics IT 

and Automation Forum. There, IT experts and users will discuss a 

wide range of topics, including the role of the cloud in logistics, mobile 

solutions, interfaces and integration, intelligent tracking and 

tracing, network planning/supply chain design, big data in logistics, 

WMS, image processing in logistics, and virtualization. 

“I am certain that CeMAT will promote greater awareness of the 

latest advances in intralogistics and the potential they hold. IT 

plays a key role as the interface that ties everything together. 

Thanks to all-encompassing software, each and every operational 

unit is fully integrated. This makes CeMAT an absolute must – not 

only for heads of production or executive managers, but also for IT 

experts. The fair provides a comprehensive look at today’s market 

and gives everyone the chance to discover the building blocks for 

tomorrow’s factories and logistic chains,” explained Dr. Christoph 

Beumer (Image 03), Chairman of the CeMAT Executive 

Committee and Chairman and CEO of Beumer Group in Beckum/ 

Germany. 

Move & Lift and Store & Load 

The biggest showcases at the fair are Move & Lift and Store & Load. 

Move & Lift is dedicated to innovations in materials handling and 

lifting technology, including industrial trucks, cranes and hoisting 

equipment, access platforms, continuous handling systems and 

port handling equipment. As well as presenting these sorts of 

machines and equipment, the showcase will explore ways in which 

they can be intelligently integrated into automated supply chains. 

Store & Load puts the spotlight on automated warehousing solutions. 

It features exhibits of rack systems, factory equipment, pallets, 

containers, loading and unloading equipment, and complete 

warehousing and loading systems. Gruchow: “Visitors of the 

upcoming fair will discover a range of semi- and fully automated 

solutions to maximize the efficiency and cost-effectiveness of their 

warehouse materials handling, loading, packaging and distribution 

operations.” 

Cranes and Lifting Equipment Pavilion 

Like other core areas of the logistics industry, the cranes and lifting 

equipment sector faces major challenges from the growing trend towards 

digital integration and Industry 4.0. In recognition of this, the 

sector will have its own dedicated exhibition area at the upcoming 

show: the Cranes and Lifting Equipment Pavilion in Hall 27. The 

exhibits will range from simple load handling attachments to turnkey 

automatic cranes. 

Platformers World@CeMAT 

Lifting and access systems are core intralogistics technologies and 

therefore rightfully rank among the big highlights on display on the 

open-air site at the upcoming CeMAT show. The Platformers 

World@CeMAT showcase will feature access platforms, mast climb- 


01 Gruchow: “Digitalization will boost logistics companies’ 

performance across all of these critical success factors” 

02 Schmel: “The positive performance of some target industries 

around the world has also been instrumental in keeping 

manufacturers’ order books full, for example e-commerce and 

the automotive industry” 

03 Beumer: “I am certain that CeMAT will promote greater 

awareness of the latest advances in intralogistics and the 

potential they hold” 


Watch more important statements of the 

trade press meeting in our video 

03 

ers, telescopic forklifts, ladder hoists, mini crawler cranes, industrial 

cranes and more from a wide range of manufacturers. 

Manage & Service 

The Manage & Service showcase brings together internal and external 

logistics. It is staged in partnership with the “transport logistic” 

trade show and features exhibits by logistics services and 

planning and consulting firms. Digitalization is revolutionizing 

entire value chains and opening up new opportunities both for 

providers of internal logistics technology and for providers of external 

transport logistics services. The future success of these 

sorts of companies hinges on the efficiency and capabilities of 

their logistics centers. Big data is a case in point. Big data means 

that complete and up-to-the-minute information on vehicles, orders 

and consignments can be accessed anywhere, anytime, 

making logistics processes much simpler to manage and control. 

Pick & Pack 

The packaging technology lineup at CeMAT 2016 will be bigger 

and better than ever, thanks to a partnership between 

Deutsche Messe and Easyfairs GmbH that will see Easyfair’s 

“Empack” and “Label&Print” shows co-staged with Deutsche 

Messe’s Pick & Pack showcase. Among this year’s exhibits will 

be the very latest packaging plant and machinery, as well as 

state-of-the art transport packaging solutions, packaging materials 

and packaging media. 

Photographs: lead photo viastore systems, Fotolia/processing: VFV Layout, 

01 – 03 Deutsche Messe 

www.cemat.com 

Visit the TVH 

stand 025 L09 

at CeMAT 

 

 

 

 

The passion, 

the people, the parts 

Parts and accessories for 

• Lift trucks and rough-terrain trucks 

• Aerial work platforms and telehandlers 

• Port and container handling equipment 

• Scrubbers and sweepers 

• … 

Our range 

• More than 21 000 000 known references 

• 600 000 different part numbers in stock 

Your benefits 

• Worldwide delivery within 24/48 hours 

• Computer-controlled stock management 

• Technically skilled staff 

• MyTotalSource: your interactive online tool 

Also second-hand equipment 

• 900 second-hand 

aerial work platform 

and forklift trucks in 

stock 

TVH GROUP NV 

info@tvh.com • www.tvh.com 

P A R T S & A C C E S S O R I E S

5 

Innovations 

you definitely 

shouldn´t miss at 

CeMAT 2016 

1 

2 

Hall 13, Booth C46 

4 


Hall 27, Booth K26 

3 

Hall 25, Both L11 


1 INTERACTIVE TEAMWORK OF 

MAN AND MACHINE 

Still´s iGo neo CX 20 interacts like a team member and 

follows its operator during order-picking at every turn. Thus, 

the operator can focus entirely on order picking, and can 

work unimpeded and error-free. Field tests have shown that 

the autonomous helper ensures a time saving of up to 30 

percent with significantly higher picking performance, 

because it eliminates the time-consuming getting on and off 

the truck. 

Pavilion P35 

2 KEEPING BAGGAGE UNDER 

CONTROL 

The Cargoswitch, a new conveyor solution by Schmalz, 

increases picking rates, can be deployed flexibly, and can be 

integrated into existing conveyor systems easily thanks to an 

open interface. Downtimes due to health concerns resulting 

from manual loading and unloading are minimized. Unit 

flow rates remain constant and productivity is increased. 

Depending on the requirements, the Cargoswitch can be 

mounted on the ground or on a mobile platform. 

3 NON-DIRECTIONAL AND 

NON-DIMENSIONAL DISCHARGE 

UNIT 

The discharge unit from Itoh Denki can discharge goods with 

a base area exceeding 150 × 150 mm (e. g. envelopes, plastic 

containers or gift boxes). Several modules can be coupled 

together to form a discharge plate. This ensures that the 

heterogeneous flow of goods can be sorted simultaneously. 

Each module has its own motor and thus operates independently. 

Maintenance times can thus be reduced to a minimum 

thanks to this magazine-based principle. 

Hall 26, Booth M13 

4 NEW BATTERY TECHNOLOGY 

CELEBRATES WORLD PREMIER 

A new generation of lithium ion batteries will be presented 

by KBK Europe GmbH (official retailer of Umka batteries in 

Europe) at CeMAT. Lithium titanate battery cells are being 

used for the first time to create the batteries. A new generation 

of rechargeable batteries have better characteristics 

than competitive gel, lead acid and lithium ion batteries. 

5 

5 TIRE INTELLIGENCE 

Contipressurecheck from the Continental Commercial 

Specialty Tires business unit continuously measures the air 

pressure and temperature of tires via sensors attached to the 

inside of the tire. The system can be complemented by the 

Contiflexbox telematics solution. It will facilitate the 

collection, displaying, and transmission of tire-related data 

to a central server. It will facilitate the collection, displaying, 

and transmission of tire-related data to a central server. The 

development plan includes also the opportunity to forward 

the data to mobile end devices. 


Fairground map 


Move & Lift (Halls 25, 26, 27, Open-air site, Pavilions 32 – 35) 

n Cranes n Series lifting equipment & platform lifts n Aerial work 

platforms n Industrial trucks, forklift trucks and accessories n AGV 

n Continuous handling systems & overhead conveyors n Port 

handling technology and logistics n Transport engineering n Complete 

installations, systems & accessories for materials handling 

Manage & Service (Hall 27) 

n Transport services n Services for logistics n Financing n Logistics 

real estate, locations and facilities n Local authorities, trade associations, 

media 

Store & Load (Halls 13) 

n Warehousing systems n Shelving systems n Factory equipment 

n Pallets, containers n Industrial doors and gates n Loading equipment 

n Complete installations, systems & accessories for warehouse 

technology n Complete logistics service packages 

Logistics IT (Hall 27) 

n Warehouse Management Systems (WMS) n Transport Management 

Systems (TMS) n Supply Chain Management Systems (SCM) 

n Hardware (e. g. Handhelds, Terminals, Displays) n Software for 

Simulation and Design n Identification Technology (e. g. Auto ID, 

RFID) n Innovative Logistics Software Solutions n Automation 

n Robotics 

Empack / Label&Print (Hall 13) 

Empack 

n Packaging machines & technology n Packaging converters n Control 

and inspection systems n Packaging materials n Components n 

Federations and media (Packaging) 

Label&Print 

n Labelling & marking technologies n Print technologies n Prepress, 

systems & software n Print finishing & converting technologies 


Supplement for international Supply Chain Management

GUEST COMMENTARY 

Understanding risks, 

boosting resilience 

Dear readers, 

Supply chain risk can hit in unexpected places: An earthquake struck 

Japan on 11th of March 2011. It and the subsequent tsunami destroyed 

towns, transportation links, and industrial infrastructure. Later that year, 

extensive flooding in Thailand affected production at more than 900 factories 

producing components for the automotive and high-tech sectors. 

In the following months, companies worldwide struggled with shortages 

of key components and materials. 

The result of a research effort at DHL’s Customer Solutions and Innovation 

team was Resilience360, a unique supply chain risk management 

solution built on three sophisticated products: a continuous assessment 

of supply chain risk and resilience, a near–real-time incident monitoring 

solution, and dedicated logistics control towers that can actively respond 

to incidents and manage business continuity. 

The Resilience360 risk assessment process maps every node in a supply 

chain – down to third- and fourth-tier suppliers. DHL supply chain risk 

experts evaluate the risk level at each node with proprietary tools, including 

country-level risk maps and DHL’s unique Supply Chain Risk Exposure 

Index. Then they build a picture of network resilience, based on the 

criticality of parts supplied, the availability of alternative sources or buffer 

stocks, and detailed surveys of supplier risk mitigation plans. 

Once an organization has built a model of its supply chain, sites across 

the network will receive immediate alerts of potentially disruptive incidents. 

Early warnings enable companies to seek feedback from supply 

chain partners, and quickly take mitigating actions, like sourcing components 

from backup suppliers. The tool logs feedback from individual sites 

too, keeping an up-to-date picture of the current state of the entire network, 

and helping managers coordinate cross-network responses 

to major incidents. 

The final element of the Resilience360 service is a dedicated 

logistics and risk control tower that evaluates the 

potential impact of supply chain disruptions by interacting 

with the supply chain partners of the customer. 

Further, it identifies mitigation strategies, such as 

alternative transportation modes or different routes, 

and manages their execution in collaboration with 

stakeholders. With Risk Response, companies get a 

complete picture of available options in the event of 

disruption, ensuring they pick the most robust and costeffective 

solution. 

Tobias Larsson is a director at DHL 

Customer Solutions & Innovation 

and Head of DHL Resilience360 



Imprint 

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Email: r.wesselowski@vfmz.de 

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Holger Seybold (Sey), Email: h.seybold@vfmz.de 

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Dipl.-Ing. Manfred Weber (MW), 

Dipl.-Medienwirtin (FH) Marie Krueger (MK) 

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Svenja Stenner 

Design/layout: 

Sonja Schirmer, Doris Buchenau, Anette Fröder, 

Anna Schätzlein, Mario Wüst 

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France 

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Great Britain, Ireland 

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Email: roberto@ts-communications.co.uk 

Italy, Switzerland 

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Sweden, Finland, Norway 

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Email: verlagsbuero-mezger@vfmz.de 

USA, Canada 

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Advertising Disposition: 

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In cooperation with: 

Hannover Fairs International GmbH 

Messegelände, 30521 Hannover, Germany 

VDMA – German Engineering Federation 

Trade Association Materials Handling and Intralogistics 

Lyoner Straße 18, 60528 Frankfurt, Germany 

Additional Partner: 

Moskauer Deutsche Zeitung 

Internet: 

www.fh-intralogistics.com 

8th year (2016) 

f+h Distribution 2/2016

xxx 

Vertical Storage Lift LogiMat® – 

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The proven technology of the LogiMat storage lift combines all the important 

functions of a powerful storage and picking system. The all-round complete 

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be tailored perfectly to individual customer requirements and guarantees an 

increase in warehouse efficiency. 

www.ssi-schaefer.com/logimat 

Visit us at CeMAT 2016 

in Hall 13, Booth C20

Reversing roles 

A huge shed. Steel sheet on top of steel sheet. The issue 

of steel logistics looks simple at first sight − But this 

impression is completely wrong. 

The weight of 10,000 elephant bulls: about 50,000 tones of steel 

are stored at Imperial Logistics International’s steel center in 

Wolfsburg, Germany. Spread over a period of twelve months, this 

means that Imperial Logistics International stores and processes 

about 1.3 million tones there. 

The steel coils and steel sheets are not half as tough as you 

might think. They like it warm and dry – an atmosphere provided 

by various infrared radiators hanging on the shed ceiling. In 

conjunction with a thin layer of oil, they prevent any white rust 

forming on the galvanized steel through condensation. This 

means that right at the start of the value-added chain, the foundation 

has been laid for the fact that today’s vehicles are less prone 

to rust than ever before. However, just controlling the temperature 

at the steel center operated by Imperial Logistics International 

is not enough. All the processes are specifically designed 

for the requirements of the companies producing and processing 

steel. As a result, both sides do not have to use costly warehouse 

space, which is usually scarce anyway. The steel center in 

Wolfsburg provides 22,000 m² of space in all. This enables 

Imperial Logistics International to keep enough material in stock 

in order to respond to short-term switches in production by the 

steel customers in a flexible manner and guarantee reliable 

supplies. There are even two emergency trucks available for 

extremely urgent requests and they can supply the pressing work 

nearby within half an hour. 

STEEL LOGISTICS

Systematic warehousing 

The coils and steel plates are transported to the pressing works 

operated by the OEM every four hours. The steel parts have usually 

already been cut to match the final dimensions of the future components. 

Depending on which vehicle models are being produced, between 

600 and 1,000 different material types are used – these types 

of steel differ in terms of their material quality and thickness. The 

final dimension production therefore demands sophisticated processes 

and meticulous quality control procedures. A coil with any 

damage on its edges, for example, would be unusable. The checks 

on incoming goods therefore play an enormously important role. 

The employees at the steel center first check all the coils for any contamination 

and damage. 

The steel is also marked with a barcode, which is attached to the 

supplier’s delivery note. This barcode not only serves as a means of 

identification. Using the warehouse-management-system, a crane 

driver can request for example additional information when he 

scans the barcode. He then knows immediately, for instance, which 

storage area is earmarked for the quantities of steel – and particularly 

how they need to be stored. Soft, thin-walled material, for 

example, can only be stored in a single layer. 

A well-balanced system 

“Ever since the center has existed, the pressing 

works have never received an incorrect or clearly 

damaged steel part from us” 

Volker Behle, Site Manager at the steel center in Wolfsburg 

Particular care is required when transporting the steel. To ensure 

that the edges are not damaged, the coils are raised with electrical 

magnets. The warehouse-management-system becomes involved 

here too: it checks during every transfer operation whether the correct 

coil is hanging on the magnet. As a result, all the processes are 

traceable and the OEM and other customers can be certain that 

they obtain the material on order. Customers can even examine the 

current status, check stocks and place orders through a web interface. 

This is a convenient solution, which also keeps the steel supplier 

well informed: it is informed as soon as the goods are being 

transported. That is also the time for the customer to pay for the 

steel delivery. This has a clear advantage: it is able to reduce its capital 

tie-up in this way. Overall, outsourcing the steel logistics is a 

well-balanced system – for all those involved. 

Photo: Michael Neuhaus 

www.imperial-international.com 

About Imperial Logistics 

International 

As a wholly owned subsidiary of the South African 

company Imperial Holdings Limited, Imperial Logistics 

International is responsible for coordinating and managing 

all the international logistics business of Imperial 

Holdings Limited outside Africa. The varied portfolio of 

services at Imperial Logistics International, which has its 

headquarters in Duisburg, is separated into two divisions: 

the Group pools all its transport services in the 

Shipping, Road and Intermodal business units in the 

Imperial Transport Solutions division. The Imperial 

Supply Chain Solutions division covers all the services in 

the contract logistics, contract manufacturing and 

warehousing sectors for the Automotive, Machinery & 

Equipment, Steel, Retail & Consumer Goods and Chemicals 

business units. 


Cost optimization 

in the returns network 

About Chair of Logistics 

Management University of St Gallen 

Martin Hänsel, Wolfgang Stölzle 

In a case study, the potential savings from the 

implementation of certified returns are examined in 

the context of media distribution. 

The Chair of Logistics Management at the University of 

St Gallen, Switzerland, provides an international 

platform for scientific and practical dialogue in the field 

of logistics, supply chain management and transport. 

The chair researches complex problems by developed 

innovative concepts, methods and instruments. It’s 

driving the development of logistics management in 

industrial, commercial and service companies and 

promotes knowledge building and transfer within an 

international network of renowned universities and 

institutes. 

LOGISTICS MANAGEMENT 

Nowadays, the market of the music industry is mainly characterized 

by a fast paced environment and a change from physical, 

digital or analogue media towards non-physical formats. Due to the 

large increase in the offer of digitalized music over the internet as 

well as music portals, the demand and sales of physical media like 

CDs or DVDs have decreased. As high sales can still be achieved, 

despite this decline, it is even more important for labels as well as 

pressing plants and distributors to position themselves as well as 

possible in the shrinking market. 

In particular, due to the increase in online retail, but also due to 

the rising number of products sold daily, there is an increase in the 

forward but also the reverse flow of goods. Since returns are not 

completely avoidable due to legal requirements, this process has 

become a part of the corporate strategy as well as an opportunity to 

influence a company’s strategy. 

In the present case study, the potential savings from the implementation 

of certified returns – a specific form of returns, which 

have so far only been applied in the publishing industry – are examined 

in the context of media distribution. 

An approach from the publishing industry 

A specific type of return – also referred to as remission – is applied in 

the publishing industry. Here, magazines, newspapers or other 

print media are often only produced for a certain period of time 

(e. g. on a daily, weekly or monthly basis). After this window of opportunity 

has passed, sending the unsold products back to the dis- 

tributor does not make much sense, as re-storage or further distribution 

to third markets is usually not possible. 

Consequently, the disposal of unneeded items is taken care of by 

the retailers, in order to reduce the shipping and handling costs. The 

electronic notification of the number of return-items discarded by 

the retailer is referred to as “certified returns” or remission. 

In summary, the following factors can be identified for a reasonable 

application of certified returns: 

n The production costs are smaller than the shipping and handling 

costs for the return. 

n A resale of the goods is not or only partially possible and the proceeds 

do not exceed the necessary shipping and handling costs. 

n Possible risks for the copyright holders of the products are backed 

by long-term partnerships with retailers. 

With the aim of illustrating the application of certified returns in 

B2B-commerce, the subject matter will be analyzed using the example 

of a media distributor. 

Returns process analysis 

In the sale of media to the end user – generally organized through 

outlets (retailers) – it is to be assumed that most of the goods pre- 

Prof. Dr. Wolfgang Stölzle is holder of the Chair of Logistics Management at 

the University of St Gallen, Martin Hänsel M.Sc. mult. is PhD Candidate and 

Research Associate at the same chair. 


sented there, do not belong to them. 

Rather, they have consignment agreements 

with the producing or distributing 

companies. As a result, the retailer has 

the opportunity to return the unsold 

items, which are then delivered as returns 

to the distributor. 

The daily number of returns at the 

examined media distributor amount to a 

total of approx. 14,000 units; which all 

have to be manually recorded, checked 

for mistakes and if necessary processed, 

re-stored or discarded by employees in 

time-consuming and labor-intense work. 

The entire return process can be divided 

into five main processes: 

1. Handling by the retailer 

2. Return transport of the items from the 

retailer to the distributor – covered by 

the retailer 

3. Handling by the distributor 

4. Processing of the returns 

5. Further transport of the no longer needed items to the disposal 

service providers 

The first two positions mentioned, handling costs (1) and transport 

costs to the distributor (2), can be attributed to the retailer. The 

total costs for the processing of the returns amount to about 900,000 

euro annually for the retailer. The internal handling costs of the distributor 

(3) consist of the proportionate wages, working capital and 

incidental costs for incoming goods as well as the transport costs of 

the returns from the receiving area to the returns vestibule. Taking 

into account the main processes (4) and (5), the total annual process 

costs attributable to returns amounted to 400,000 euro. 

Non-physical returns as an optimization approach 

With the aim of facilitating the decision on the further use during 

the quality check, so called return-usage-codes (RUC), which can 

either be automatically entered based on the inventory changes or 

adjusted manually by employees. Once the barcode of an item has 

been scanned, additional information on the basis of the RUCs will 

be displayed on the monitor for the employees. This can be information 

about specific storage areas, but also about disposal indicators 

(off-indicators). In the case of the latter, the product needs to be 

destroyed, regardless of its condition – for example due to excess 

inventory or outdated content. According to the analysis of data 

form the 2014 financial year, 20% of all items at the examined distributor 

were marked with an off-indicator. 

Although the disposal of these products is to be carried out, regardless 

of their condition, they are first sent to the distributor for a 

quality check before being sent to a local disposal service provider, 

where they are disposed of (= waste products). Waste products 

therefore go through two processes, each of which is characterized 

by high labor costs. This results in an annual total of approx. 623,000 

items, whose transport for the retailer to the distributor could be 

saved through the use of “certified returns.” 

Impact of the returns process and process costs 

In comparison to the initial situation, the additional information on 

the RUC of each article being provided by the distributor is a prerequisite 

for the application of the remission approach. Thereby the retailer 

has the opportunity, using a special picking list, to gather all 

the items marked with a disposal-indicator and transport these to 

the respective local waste disposal service provider. 

Another change in comparison to the initial situation arises from 

the returns-notification of the retailer to the distributor. This 

Process visualization after the implementation of certified returns 

notification must include a list of all the returned items as well as all 

the disposed products. In the case of the waste products, this counts 

as a certified return, since no physical media is returned to the 

distributor. 

The examinations have shown that a reduction in the daily 

amount of return items by 20% accordingly reduces the distributor’s 

labor costs for the returns processing. The annual savings for the retailer 

– divided into transport and picking costs – nevertheless 

amount to approx. 6%. In order to increase the attractiveness of this 

procedure for the retailers, the disposal costs, which would otherwise 

fall upon the retailer, should fully or partially be allocated to 

the distributor. 

The Figure summarizes the changes to the returns network 

between the distributor and the retailer (target-state), with the 

improvements to the process costs, in comparison to the initial 

situation, which can be achieved. 

General recommendations for action 

The implementation of certified returns – so far only known in the 

publishing industry – provides the opportunity to reduce the costs 

between the distributor and the retailer. It has been shown using the 

example of a media distributor that the achieved savings depend on 

the proportion of waste products. It is assumed that this proportion 

increases particularly for low-value items as well as products with 

low production expenses. An equivalent application of the returns 

process is conceivable for example in the textile industry. The procedure 

is also equally applicable for higher-value products, for 

which the reuse of parts or components is desirable. Merely the 

simplified identification by the picker and the existence of a local 

third party provider for the disposal logistics must be ensured. 

A mandatory prerequisite for the introduction of remission in 

B2B-commerce is the clear identification of the product classification 

in disposal or processing. While generally all print media of a 

certain type can be counted as a waste product, an unambiguous 

classification using the RUCs is possible in the case study of the media 

producer and distributor. An assessment based solely on the visual 

characteristics of an article is conceivable in principle, but 

would probably require extensive training and additional knowhow 

of the pickers, which would again increase the costs – especially 

labor costs. 

Photograph: lead photo: Pixabay / DS-Foto, Figure p. 37 University of St Gallen 

www.logistik.unisg.ch 

Source: University of St Gallen 


The ten most high capacity airports 

in Europe form part of the global 

production and supply chain 

London 

1,51 

Mio. t 

Paris 

0,53 

Mio. t 

0,38 

Mio. t 

0,67 

Mio. t 


Brussels 

Liège 

Luxembourg 

Amsterdam 

1,56 

Mio. t 

Cologne-Bonn 

2,09 

Mio. t 

Frankfurt 

0,87 

Mio. t 

Leipzig-Halle 

1,49 

Mio. t 

0,72 

Mio. t 

Milan 

0,43 

Mio. t

Planes are the preferred means of the transport used to 

connect people with the rest of the world in a short 

amount of time. However, it is not just people who are 

transported by plane and “processed” at airports but 

also a variety of particularly capital intensive goods. 

According to our own rankings (as at 2013), we manage 

the ten most high capacity airports in Europe relating to 

the quantity of freight handled in tones. 

Goods transported by plane are not just processed by cargo planes 

but a large part of the airfreight volume is shipped in the belly of 

commercial aircrafts. In technical jargon, this combination is referred 

to as “belly cargo” − freight and passenger traffic are thus closely interlinked 

and dependent upon one another. 

When it comes to transporting freight, planes are predestined for 

shipping time-sensitive, quickly perishable and high-value cargo due 

to the high speed and safety levels they offer. 

If you just consider the pure weight of goods transported around the 

world, airfreight only accounts for a proportion of less than one percent 

− however when the pure goods value is taken into consideration 

this share rises to 40 percent. Due to the economic share of high value 

goods, for example from the communication and data processing sector, 

increasing in comparison to that of bulk goods, the short transport 

times are particularly important despite high freight costs. If a highvalue 

product, such as a smartphone, is to penetrate the market quickly, 

transport by plane is still an unrivalled solution. 

Airfreight ensures that international markets are connected over large 

distances in a timely way via the supply chain. However, to ensure that 

goods can be supplied to markets without long interruptions to the 

supply chain, airports, as the load bearing infrastructure of airfreight 

transport, do not just have to process the arrival and departure of 

planes. As a transport hub, an airport is also responsible for the continued 

transit of passengers and cargo. It is therefore important that airports 

have excellent rail and road connections or have links to the river, 

canal or sea shipping sector (intermodal transport links). Airports 

should also have enough space for freight terminals. The necessary infrastructure 

of a freight terminal must include freight receipt and dispatch, 

a sorting and storage area as well as a freight loading area, storage 

rooms for special freight and an administrative building. 

Special pallet and container unit load devices (ULD) are, amongst 

other things, used to load the freight on to planes. These are usually 

made of aluminum, fitted with connections to hold cargo netting and 

enable large amounts of cargo to be bundled in large units. 

As the shipping documents for the airfreight must be uniform and 

the abbreviations that are used must be understood internationally, international 

airlines have joined forces to regulate this and have formed 

the International Air Transport Association (IATA). The first objective 

of the IATA is to standardize all of the handling processes that are implemented 

when transporting passengers and cargo. The IATA code – a 

combination of three Latin letters – is used for the unique identification 

of individual commercial airports and is stipulated in our ranking 

for the relevant airport. 

Airfreight enables Europe to be connected to international production 

chains around the clock. Speed, flexibility and reliability of companies 

are the most frequently reported reasons why planes are selected 

as the means of transport. 

Text: Manfred Weber 

Graphics: Fotolia/processing: VFV Layout 


Ranking 

1 

Frankfurt on Main (Germany) 

Frankfurt on Main airport (IATA Code: FRA) is 

also called Rhine Main Airport in local slang and 

in its own description is titled Frankfurt Airport. 

It is considered to be Germany’s largest passenger 

airport and occupies first place in our ranking 

according to air-freight handled in Europe. The airport 

was opened in 1936, covers an area of approx. 2160 ha as 

well as having four runways for take-off and landing. In 

2013 the tonnage shipped was over 2 095 000 t, which 

showed an increase of 1.42 % in comparison to 2012. The 

operating company for the airport is Fraport AG. 

4 

Paris-Charles de Gaulle 

(France) 

This airfield named after the 

French General and statesman 

Charles de Gaulle (IATA code: CDG) 

is the international hub for Air France and is 

situated some 26 km north-east of Paris city 

center. The airport is connected to public 

infrastructure by the high-speed TGV train 

amongst other things. In our European 

comparison this airport – opened in 1974 

– with 1 494 900 t of freight shipped per 

year lies in fourth place, in which case 

freight handled from 2012 to 2013 was 

negatively impacted by -1.26 %. The area 

covered by the airfield is put at 3 500 ha, 

with four runways for take-off and landing 

as well as three terminal buildings. The 

operating company is Aéroports de Paris 

(ADP). 

2 

Amsterdam Schiphol (Netherlands) 

Lying four meters below sea-level this is one of the 

lowest airports in Europe. Having opened as early as 

1916, the airport extends across an area of 2 787 ha 

with six runways for take-off and landing and one 

terminal building with three departure halls. In 2013 freight 

handled was 1 566 000 t – an increase of 3.64 % over the 

previous year. The IATA code is: AMS, the operating company is 

Schiphol Group. 

5 

Leipzig-Halle (Germany) 

Called “Schkeuditz” in the local 

jargon, Leipzig/Halle airport is 

situated some 16 km north-west of 

Leipzig and 22 km south-east of Halle 

(Saale) near the town of Schkeuditz. This 

airport covering some 1 400 ha was opened in 

1927 and has two runways for taking off and 

landing as well as two terminal buildings. The 

company Flughafen Leipzig/Halle GmbH is 

given as the operator for this airport with IATA 

code: LEJ. From 2012 to 2013 an increase of 

some 3.7 % in freight shipped to a value 

877 300 t could be recorded. 


3 

London Heathrow (UK) 

London / Heathrow Airport (IATA 

code: LHR) occupies third place in 

our ranking with freight of 

1 513 700 t being handled each 

year. From 2012 to 2013 however the 

airport showed a decrease in the annual 

amount of freight of 2.72 %. 

London / Heathrow lie some 24 km west of 

London and is operated by Heathrow Airport 

Holdings. It has two runways for take-off 

and landing and covers an area of 1 333 ha, 

as well as having five terminal buildings. 

The airport was opened in 1946. 

6 

Cologne-Bonn (Germany) 

At a distance of some 15 km from the cities 

of both Cologne and Bonn, “Konrad 

Adenauer” airport lies exactly in the 

middle between the two cities Cologne- 

Bonn. Although the area covered by the airfield is 

only 1 000 ha, there are three runways for taking off 

and landing there and two terminal buildings. The 

amount of freight shipped at 721 700 t per year lies 

in the middle of the ranking – however from 2012 

to 2013 it showed a falling trend of -1.15 %. The 

opening of the airport with IATA code: CGN goes 

back to the year 1938. Flughafen Köln/Bonn GmbH 

operates the airport. 


7 

Luxembourg (Luxembourg) 

The international airport of Luxembourg 

(IATA code: LUX) – often called “Findel” 

unofficially after a small neighboring town 

– is the only international airport in 

Luxembourg. It was opened in the year 1947, although 

its beginnings extend back to the 1930’s. The operating 

company, the Administration de la Navigation 

Aérienne (ANA), looks after one runway for take-offs 

and landings as well as two terminal buildings − however 

Terminal B is not in use at the present time. With 

673 400 t of freight handled in 2013, and with a 

growth rate of 9.44 % between 2012 and 2013, the 

airport displays considerable performance data. 

8 

Liège-Bierset (Belgium) 

The airport Liège-Bierset (with IATA code: 

LGG) is the classification for the Belgian 

(freight) airport, situated some nine 

kilometers to the west of the city of Liège 

in Bierset. The operating company is Liège Airport 

S.A, which runs the airport with its two runways 

for take-off and landing as well as one terminal 

building. The city of Liège and its airport covering 

some 300 ha are situated at the center of the Paris 

– Amsterdam – Frankfurt on Main triangle. 66 % 

of European air freight arising are handled in this 

region. Handling freight of 534 200 t a year and 

with a growth rate of 4.69 % the airfreight 

handling location in Liège occupies eighth place in 

our European comparison. 

9 

Milan -Malpensa (Italy) 

Milan Malpensa airport (IATA code: 

MXP) is the second largest international 

airport in Italy following Rome 

Fiumicino. Situated 46 km northwest 

of Milan it extends across an area of 

1 100 ha. The first airport was opened by the 

aviation pioneers Giovanni Battista Caproni 

and Giovanni Agusta as early as 1909. The 

modern airport today has two runways for 

take-off and landing, two terminal buildings 

and in 2013 recorded freight of 430 300 t 

shipped with a growth rate of 3.87 % between 

2012 and 2013. 

10 

Brussels Airport 

(Belgium) 

Brussels Zaventem Airport 

(officially Brussels Airport) 

lies 12 km north-east of the 

Belgian capital of Brussels in the 

Flemish region of Zaventem and for 

this reason is also called Luchthaven 

Zaventem or Aéroport de Zaventem. 

The opening of the airport operated 

by the Brussels Airport Company SA 

(IATA code: BRU) goes back to the 

year 1940. Air traffic is realized on 

the three runways for taking off and 

landing as well as in the two 

terminal buildings. In 2013 the 

weight of freight handled was 

378 700 t – however this meant a 

decrease of 6.56 % in comparison to 

the year before. 

Between 2006 and 2007 Brussels- 

Zaventem was the most punctual 

airport in Europe. 

The 10 most highly 

performing freight 

airports worldwide 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

Hong Kong 

Memphis 

Shanghai 

Seoul 

Anchorage 

Dubai 

Louisville 

Tokyo 

Frankfurt/Main 

Taipei 

Source: Eurostat 


Islamic Republic of Iran: 

Facts and figures 

Area: 

1,648,195 square miles 

Length of the coastline: 

2,440 miles 

Fixed telephone lines: 

390 per 1,000 inhabitants (2014) 

Mobile telephone connections: 

878 per 1,000 inhabitants (2014) 

Inhabitants: 

2015: 78.6 million 

Population density: 

2015: 47.7 inhabitants/ mile² 

Population growth: 

1.2% per year 

Gross National Product 

(GNP, nominal): 

2014: 416.5 billion US$ 

2015: 396.9 billion US$ 

2016 Forecast: 

416.2 billion US$ 

2014 

2015 

2016 

Capital: 

Teheran: inhabitants around 12 million 

Business: 

BUSINESS AND ECONOMY 

Infrastructure: 

Rail network 

(Length and standard gauge): 

8,483,5 miles (2014) 

Road network (hard top) : 

160,366 miles (2010) 

Water ways: 850 miles 

Container ports: 4 (2014) 

Import: (2014) 


Export: (2014) 


Gas: 

Production (billion cubic meter): 172.6 (2014) 

Reserves (trillion cubic meter): 34 (2014) 

Oil: 

Production (thousand barrels per day): 

3,614 (2014) 

Reserves (billion barrel): 158 (2014) 

Source: Germany Trade & Invest (GTAI) 2015, Auswärtiges Amt Germany 

Graphics: VFV, Sonja Schirmer 



Preview 3/2016 

Supply Chain Management 

From an embargo to a consumption 

frenzy? 

In the North, Iran borders the Caspian Sea and in the South 

the Persian Gulf. Direct neighbors include Turkey, Iraq, 

Azerbaijan, Armenia, Pakistan and Afghanistan. 

The country’s most important industrial sectors include the 

oil and gas industry, the petrochemical industry as well as the 

automotive and metal industries. Currently, the economy in 

Iran is predominantly directed and controlled by the state and 

religious foundations, although the private commercial sector 

is set to be noticeable strengthened and developed in future. 

Despite its continued large reserves of oil and natural gas, the 

country is striving to develop renewable energies. The main 

aim is to use wind power and solar energy to make the 

country less dependent on fossil fuels in future. With state 

funded projects, the government also wants to give international 

companies investment incentives. 

Around two thirds of the population in Iran are less than 

thirty years old, are well educated but are not happy about 

the strained economic situation in the country. In addition to 

local problems, the economic crisis is mainly a consequence of 

international sanctions. The sanctions against the oil and 

financial industries have had a particularly negative effect. 

On January 16, 2016, the United Nations and European Union 

lifted their economic and financial sanctions against Iran as 

part of the nuclear agreement reached in Vienna, Austria. The 

USA slightly relaxed restrictions implemented by their 

bilateral trade embargo. Iran can once again export an 

unlimited amount of oil and gas and has access to international 

payment transactions. 

Europe is expecting a significant increase in the trade volume 

following the abolishment of the financial and economic 

sanctions. An important indicator of this was the high level of 

consumer spending, especially by the younger population, 

once the embargo was lifted. This assumption is further 

corroborated by the continuing high levels of per capita 

income of USD 16,463 (IMF estimate 2014). 

Text: Manfred Weber 

There are laws and ordinances under law that restrict the 

“freedom of foreign trade”. For this reason all companies 

must observe their permitting obligations, prohibitions and 

restrictions. One speaks in this context of export control 

regulations. 

Clearing Formalities 

Following the adoption of standards to secure and facilitate 

global trade through the World Customs Organization (WCO), 

there are very high demands on a specific description of the 

goods. Moreover, the requirements for a secure supply chain 

have increased. 

Global Business 

Indonesia – a growth market 

For several years Indonesia’s high economic growth has 

continued. The largest island state in the world is one of the 

most dynamic countries in Southeast Asia and is strongly 

influenced by the expanding domestic market. Furthermore, 

the European Union is negotiating with Indonesia about the 

free trade agreement “Comprehensive Economic Partnership 

Agreement” (CEPA). Is Indonesia the right marketplace to 

invest in? 

Closing date: 16.08.2016 

Publishing date: 07.09.2016 

f+h Intralogistics f+h Distribution 3/2015 2/2016 43

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f+h Intralogistics 2/2016

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