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A Logistics Project in Hungary bursting with Energy - High Bay for HELL

The ultra-modern plant in Szikszó of Hungarian beverage producer HELL has a new landmark: The high bay warehouse for more than 31,000 pallets erected by Aberle GmbH is one of the largest warehousing complexes in Hungary. It smoothly fits into the almost entirely automated can production and filling facility for these „hellish“ energy drinks.

Not less than 7 million times a day a can of HELL Energy Drink is being opened around the world. With this out-put HELL Energy Magyarország Kft. is one of the most successful producers of these invigorating functional drinks and at the same time one of the fastest growing FMGC-trademarks in the world. Founded in 2006, growth rates have always been in a double-digit range since then. Already in 2009, HELL was market leader in their homecountry Hungary and added in the meantime nine other countries, e.g. Bulgaria, Romania und Greece. And there are clear signs for further growth. Plans go for a distribution coverage of at least 80% in the current export countries and the opening up of new markets. With the additional capacities created by the commissioning of the new high bay warehouse in spring 2019, the company laid the foundation for further expansion. Currently HELL sells around 2,5 billion cans a year with the characteristic devil logo in more than 50 countries. On top of this come White-Label commissioned filling and products of company-own Sublabels such as Zygra or Slang. Still widely unknown in Germany, HELL is in many countries already a big name – and now also in the literary sense: The company logo on the warehouse facade has a stately size of five meters.

Consistent Automation Concept

Since 2011 HELL ENERGY produces with an own production- and filling-plant operating 24/7 on 365 days a year according to FSSC 22000-Standard in the Szikszó facility. In this context the company opted for a high vertical manufacturing range from can production up to filling. Virtually every production step is performed under the company’s own direction. The water comes from the company’s own wells, the cans from own manufacturing – Hungary’s first aluminum beverage can plant operating since 2017. Even marketing and promotion material is produced by HELL themselves to guarantee a consistent customer experience from point of sale until enjoying the drink. Every production step is automated where possible, and robot-supported to a large extent. Correspondingly, the general requirements for planning and erecting the high bay warehouse and conveyor system have been very demanding. The customer‘s objective was to establish a new center and linchpin of a consistent automation concept from production lines up to the loading ramps. „We were looking for a partner, able to master the realization of highly complex automation projects“, Tarsoly Elemér, Project Director at HELL states. Aberle GmbH, manufacturer-independent systemintegrator, was awarded the order as general contractor for steel rack construction and metal works, sprinkler and fire alarm system, stacker cranes, conveyor system and controls. In the past Aberle has already erected numerous new logistic systems for companies in the food and beverage sector with great success and knows about the particular requirements of the industry. As a part of Business Area Logistics Systems of international technology group Körber, Aberle’s specialists have expertise in implementation and coordination of transnational projects. Elemér remarks: „Especially the presence of a Hungarian project manager of Aberle at site has made communication much easier and contributed to a smooth process.“ This also shows the quick completion of the project – after only 13 months construction time the new system was put into operation, while all processes in the plant continued without any interferences.

Intelligent Material Flow

Aberle’s experts erected a six-aisle high bay warehouse in silo design with 31,152 pallet storing positions, a floor space of nearly 6,000 square meters and 30 meters height. It complements the existing 6,000 square meter warehouse for raw and packaging materials as well as two product warehouses with a capacity of 36,000 pallets and forms the new heart of the plant. Each aisle of the new warehouse has been furnished with an automated stacker crane with double-deep fork and camera systems. Additionally Aberle implemented an extensive conveyor system with link to two production halls, empty can production as well as picking and distribution areas. Via two conveyor bridges with a total length of 250 meters the empty cans are transported from production to the filling halls, before being stored in as complete units on euro pallets. Output is also carried out fully automated right to the gravity roller conveyors at distribution. Only the loading of the trucks at the 10 truck loading gates is done manually with lifting trucks. „Integrating the new warehouse in the processes, which are automated to a high degree, has been a challenge in terms of planning and commissioning“, Andreas Ebert, CEO of Aberle GmbH states, „which we were able to manage standing shoulder-to-shoulder with our customer.“ Taking into account the complexity of the project the solution concept had been developed together previously in intensive cooperation of Aberle and the customer.

All processes are organized by the material flow control also implemented by Aberle with interface to the warehouse management in SAP WM. As an SAP service partner Aberle specializes in individual software solutions within an existing ERP environment. As a basis the company-own software modules Aberle PMS-M for material flow control and administration of storing positions as well as Aberle PMS-V for visualizing processes and conveyor status have been used for HELL. Intelligent material flow not only ensures high operative reliability and availability. In interaction with strongly performing system components, this enables also high dynamics, which can even be increased by an intelligent concept for peak times. During the early hours, when there is high activity at the truck ramps, the entire system performance may be focused and concentrated solely on output. The 140 double cycles per hour are then transformed into approximately 300 retrievals per hour. `Gives you power like hell´– this HELL-Slogan thus also fits the new high bay warehouse. „The system offers a high and appropriate performance“, Ebert remarks, „after all, HELL, as a sponsor of numerous Rallye- and Drift-Events and a talented driver in the wellknown WTCR series, has declared speed and dynamics as core of their brand.“ Even the robotsupported opening ceremony of the new warehouse in February 2019 was characterized by dynamics and automation. Starring Titan the Robot, intoning the hymn of the evening – High(b)way to Hell …