The Störtebeker Braumanufaktur is showing pioneering spirit – not only in regard to new types of beer and an extremely stringent marketing concept but also when it comes to expanding its production capacities: in its filling / packaging operation, and its IT and intralogistics, the brewery has now opted completely for the House of Krones, thus coping successfully with even highly complex production sequences.
Krones’ scope of supply included not only a new energy-efficient bottling line rated at 40,000 returnable glass bottles an hour but also a high-bay warehouse with just under 30,000 pallet slots from System Logistics, plus full-coverage networking of the production operation with solutions from Syskron and Triacos. The existing bottling line, the new one, a kegging line and the high-bay warehouse, plus the empties sorting system and goods dispatch zone, are all interconnected via a floor track system.
Highly complex Varioline
The principal task here was to streamline the complex work sequences involved, thus upgrading the production operation’s efficiency: “As I always say, here on our premises we’ve got ten breweries in one because each of our beers is packed in its sort-specific crate,” is how Jürgen Nordmann, the owner of the Störtebeker Braumanufaktur, describes the situation. Störtebeker’s beers are offered in the brewery’s own uniquely distinctive crates and likewise in closed sixpacks. This is why the brewery opted for the Varioline packaging system that can handle not only crates and closed baskets but another 16 different packaging variants as well.
Störtebeker’s Varioline system is the most modern version currently up and running – since it is the first to feature the new TIA control system from Siemens, enabling a maximum degree of automation to be achieved. Yet another beneficial side effect is this: the layout installed at Störtebeker takes up only about half the space that traditional packaging kit with the same output would need.
Holistically conceived logistics and IT concept
The fully automated high-bay warehouse and the associated warehouse control system were delivered by System Logistics. The warehouse with its eight aisles provides just under 30,000 slots that are served by six storage and retrieval units. The floor track system supplies the warehouse both with empties, like bottles and crates, and with ready-for-sale packages.
Furthermore, Störtebeker dedided to have Syskron’s subsidiary Triacos modify its existing SAP system to suit the new production landscape, and to link it up to various IT solutions from Syskron’s SitePilot Suite, such as Line Management, Line Diagnostics and Manufacturing Intelligence. The brewery has thus succeeded in harmonising purchase orders, business processes and production planning with each other to optimum effect. Thanks to Edge Device, moreover, Störtebeker has been able to integrate its existing Krones glass line into the overall concept.
“When we concluded the contract with Krones in 2017, it was important to us that Krones would be supplying not only the bottling line but also the intralogistics with the high-bay warehouse, and that the customising work needed for the SAP system, plus the SitePilot automation solutions, were all constituent parts of the order,” is how Jürgen Nordmann sums up their requirements. “We had already turned our attention to the subject of Industry 4.0 at quite an early stage and went looking for some suitable partners. With this investment, we have taken another crucial step in that direction, and we hope we’re now in good shape to meet and master the challenges of the future.”