No results
    Image credits:

    Plzeňský Prazdroj


    Fully automated, eco-friendly warehouse for Plzeňský Prazdroj

    You need to accept cookies to use this functionality.

    More storage space, more efficient processing and faster dispatch: Plzeňský Prazdroj’s new fully automated warehouse has enabled the Czech brewery to optimise costs while also prioritising sustainability by investing in future-viable technologies.

    Pilsner Urquell, a Plzeňský Prazdroj’s most famous brand, was the first beer made using the brewing method originally developed in Pilsen. Today, almost all known lager beers are based on this formula. The Czech town of Pilsen, which gave its name to this tradition-steeped drink, is home to the country’s largest brewery, Plzeňský Prazdroj. It has made Pilsner beer since 1842 and is acknowledged as the Czech Republic’s biggest beer exporter, with consignments shipped to more than 50 of the world’s countries.

    Image 37078
    Pilsner Urquell is the model for many lager beers worldwide. Image credits:

    Plzeňský Prazdroj

    Sustainability meets the latest state of the art

    Plzeňský Prazdroj decided to build a new warehouse, in order to keep on using the original recipes and tried-and-tested methods and at the same time facilitate daily routines and guarantee maximum quality levels. The Pilsen brewery had precisely specified requirements for it: The new warehouse should be innovative and fully automated and effectively support the people working there. At the same time, Plzeňský Prazdroj wanted to reduce both costs and CO2 emissions, increase the storage space available and speed up dispatch of its own bottled and canned beers as well as processes in general.

    “Plzeňský Prazdroj knew exactly what they wanted: an innovative, automated warehouse that saves costs and reduces the carbon footprint. A customer request that suits us well: cost-cutting and sustainability are two issues frequently required for the solutions we sell,” Ralf John, Head of Technical Operations at System Logistics, explains. 

    For its new, fully automated warehouse, the tradition-steeped brewery has opted for a solution incorporating the latest state of the art from Krones’ subsidiary System Logistics. The result is highly impressive: a new, self-contained high-bay warehouse measuring 10,000 square metres and providing approximately 16,000 pallet slots. That is roughly equivalent to 18 million bottles of beer, which means the brewery has 20 percent more storage capacity. Ten storage and retrieval units, each of which can transport two pallets, move the pallets into and out of the pallet slots. An automatic monorail with a total of 28 travelling carriages, which is 500 metres long, takes the fulls from the bottling hall to the warehouse, thus saving both space and transport costs.

    Goods dispatch capacity increased by 50 per cent

    In the warehouse, the bottles and cans are directly taken off the monorail by automatic storage and retrieval units, which feature an energy recovery system so as to reduce power consumption. As the name implies, the monorail is rail-based, so fork-lift trucks are used only for loading the lorries that collect the merchandise. And these fork-lift trucks are now electrically operated instead of running on liquid gas as before.

    The beer is automatically transported from the warehouse to the dispatch area as required. Since it is now possible to retrieve up to 290 pallets per hour from their slots, dispatch capacity has risen by 50 per cent. Ecological considerations have also been factored into the design of all these improvements. For example: reduction in CO2 emissions (around 500 tons of CO2 less per year) because using a monorail makes for a significantly smaller number of pollutant-emitting fork-lift trucks. What’s more, the storage and retrieval units are fitted with a state-of-the-art energy recovery system.

    Since we’d already been informed about plans for a future warehouse expansion, we’ve been able to factor that into our concept and minimise even now any possible effects a future expansion job (Phase 2) might have on daily operation. This enabled us to come up with a solution extending beyond tomorrow. Erwin HächlRalf JohnHead of Technical Operations, System Logistics

    Project: Building an automated high-bay warehouse
    Customer: Plzeňský Prazdroj
    Location: Pilsen, Czechia
    Commissioning: November 2022
    • Ten storage and retrieval units
    • 540-metre-long monorail with 28 vehicles
    • Pallet slots for approx. 16,000 pallets
    • Material flow / Performance: 320 pallets per hour in and out
    • Dimensions of high-bay warehouse: 54 x 70 x 30 metres

    Want to read more Krones stories?

    You can easily send a request for a non-binding quotation in our 

    Request new machine