One-stop system integration

Every day, up to 6,000 beverage pallets leave Hassia Mineralquellen's distribution centre in Bad Vilbel, Hesse. To handle this enormous volume -managed via a new online ordering portal-the intralogistics processes mesh together perfectly thanks to a high degree of automation. A particular logistical challenge arose with the relocation of the traditional Rapp's juice factory and cider mill. The solution: To maintain high-performance mixed-pallet order picking, the capacity of three existing automated storage systems used for buffering reserve pallets was expanded with an additional automated storage and buffer system. As the general contractor, the Hamburg-based intralogistics specialist STILL took charge of the implementation, completing the project in just six months and activating the system during ongoing operations with a precise go-live over a single weekend.

Centralisation at the headquarters

The dimensions in Bad Vilbel are enormous: seven filling lines handle up to 2.8 million bottles per day. The beverages are stored in four automated high-bay warehouses with space for 100,000 pallets. Thomas Bobe, Head of Internal Logistics at the distribution centre, explains Hassia Group's logistics strategy: "In an increasingly competitive environment, we have combined ecological and economic measures by consolidating the production and distribution of our sites here at the headquarters, optimising both our intralogistics processes and the entire supply chain."

During peak order periods, the Hassia team loads up to 150 lorries in 24-hour operation. Single-variety orders are processed as full pallets, transported directly from the high-bay warehouse to dispatch via overhead conveyor and roller conveyor systems. However, handling mixed pallets is significantly more complex. Alexander Orsiwskyj, Head of Internal Logistics, highlights the operational challenge: "A quarter of the pallets delivered daily to our retailers are mixed pallets containing various beverage brands. Manual order picking alone can no longer handle the performance requirement of up to 100 pallets per hour!"

From supplier to general contractor

To resolve this bottleneck, four automated warehouses now operate around the clock for the order picking of mixed pallets. Via replenishment control, single-variety beverage full pallets are flexibly stored in one of the 200 available pallet slots using an automated storage and retrieval system (ASRS) or are directly fed to the respective pick positions via gravity roller conveyors. After order picking, the contour-checked mixed pallets are transported either directly to dispatch via the respective stacker crane and the connected continuous conveyors or buffered in the racking warehouses for delivery. Gürhan Hangişi, Project Manager at STILL, adds regarding the ergonomics of the workstations: "With our low lift pallet trucks of the EXH-S type, beverage packs can be placed ergonomically and comfortably on the pallet using the raised forks, and the pick positions at the gravity conveyors can be quickly approached and processed."

Originally, STILL was only intended to be the supplier for the new racking systems. However, in-depth process analyses and the proven partnership convinced Hassia Mineralquellen's project management to entrust the Hamburg-based intralogistics specialists as the general contractor for the entire project. Kai Freitag, Business Development Manager for Automated Solutions at STILL Hamburg, summarises the solution approach: "STILL has an extensive experience of over 100 years in the applications of our electric vehicles and their automation-now for over 30 years-we can develop tailored and rapid solutions for almost any intralogistics challenge our customers face."

Precise implementation during ongoing operations

The project's implementation resembled open-heart surgery: the system was built within six months while operations continued, and the final commissioning took place over just one weekend. This involved dismantling old conveyor technology, pouring new foundations, and installing all the hardware, including the storage and the stacker crane. The new systems operate autonomously using sensor technology, eliminating the need for complex interface programming.

"To meet the deadlines, our focus was particularly on integrating the various trades-coordinating external suppliers as well as Hassia's internal IT and logistics," Hangişi describes the critical project phase.

Conclusion

STILL's system integration delivered clear, measurable results for Hassia: the system achieves 100 pallet movements per hour, maintains an overall availability of 98%, and contributes to handling the daily volume of up to 6,000 pallets in dispatch-while significantly relieving order pickers through ergonomic solutions. As the general contractor, STILL coordinated suppliers, IT, and logistics, minimised interface risks, and implemented the project within six months during ongoing operations. The operational added value is evident in predictable availability, stable throughput rates for mixed pallets, reduced physical strain on employees, and greater planning reliability in dispatch. For future projects, a data-driven approach is recommended:

Measurable KPI performance indicators, which evaluate progress and success in the project based on strategic goals, as well as ROI figures for financial planning, support the consistent integration of technology and personnel. These analyses ensure the economic and long-term impact of automation-the Hassia project confirms this approach.