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- Offer Profile
- For more than 40 years
Klinkhammer stands for intralogistics, automatic high-bay warehouses or
small-parts warehouses, conveyors, picking solutions, and material handling
which are optimally adapted to the flow of materials and really simplify
By taking a holistic 360° approach, the Klinkhammer Group offers a
comprehensive range of services for the implementation of automated
A well-planned warehouse also needs optimum warehouse equipment. As system- and market-independent provider, the Klinkhammer Group can choose from a wide variety of products and services and thus offer the best options available on the market. No matter if conveyor systems, small parts storage shelving or pallet racks, drive-in, flow or high-bay racks, container concepts or complex shelving systems - it is always important to adapt the solution perfectly to the warehouse topology and the requirements of the goods to be stored and to match it to the components employed and the warehouse concept. Consequently, the warehouse equipment is vital for ensuring the best possible warehouse performance. This is why the Klinkhammer Group focuses on this issue and relies on customized solutions made of standardized components.
For many controllers warehouses are still a controversial subject. The times, however, of never-ending halls full of redundant stocks on hand are over. Instead of holding large quantities of raw materials, semi-finished goods and finished goods in stock, warehouse systems nowadays are characterized by efficiency and dynamics. Furthermore, completely new possibilities to use the existing storage space are available thanks to modern high-bay systems and automatic warehouse vehicles. Hence, it is good to have a partner who is a specialist in warehouse systems.
For More Storage Capacity and Optimum Utilization of Space
Automated high-bay warehouses are used for the storage of packaged goods. Thanks to the compact design a high space utilization and storage density can be achieved. Such high-bay warehouses are operated by automatic storage and retrieval cranes which get their transport orders from a warehouse management and material flow system. Complex control systems are responsible for controlling the machines (e.g. Step 7). Conveyors transport the goods to be stored to the high-bay warehouse and from this area to the order picking zone, to the production area or to the shipping department. Our storage systems are available in various configurations and designs, from single-deep or multiple-deep storage to built-in shelving or silo.
Purpose of high-bay warehouses
- Deep-freeze store
- Central store
A small-parts warehouse is designed for lightweight, small units that are stored in totes, cardboard boxes or on trays. Klinkhammer offers systems tailored to your individual needs and analyses which type of small-parts warehouse suits best to your requirements depending on the load supports, loaded goods, performance requirements and fields of application. The existing storage space is optimally used, thus guaranteeing high profitability. Automated small-parts warehouses are operated by means of storage and retrieval cranes or shuttles.
Small-parts warehouse design types (also multiple-deep)
- Racking storage system
- Bin storage system
- Compact warehouse
- Tray warehouse
- Warehouse operated by a walking beam conveyor
- Drawer system
KlinCAT multilevel shuttle system
High-performance multilevel shuttle system in lightweight design
KlinCAT® stands out for its compact design and its low weight and substantially contributes to an enhanced dynamics and a higher throughput. When comparing the drive parameters to automatic storage/retrieval cranes featuring a speed of around 5 m/s and to shuttle systems featuring a speed of around 2 m/s, KlinCAT® reaches powerful 4 m/s. Other advantages: Small bottom and top approach dimension to ensure a high storage density, an innovative, energy-efficient drive concept and low maintenance and investment costs.
Advantages compared to AS/RS
- High performance, multiplied throughput
- Flexible and adaptable
- Scalable thanks to modular structure
- Easy maintenance, each shuttle level can be reached by foot
Advantages compared to shuttle
- Low investment despite high performance
- Easy maintenance, less devices, easily accessible
- Access to several levels
Benefit From Experience
Conveyors installed in the warehouse guarantee that goods of all size and weight categories reach their predefined destination without interrupting the in-house transport. From the goods in department to the high-bay warehouse, from the automated small parts storage to order picking and consolidation and finally to the shipping department. The transport media, however, can be very different: Chain, roller or modular belt conveyors, vertical conveyors / lifts or transfer carriages – there are various options.
Thanks to our experience in mechanical engineering and as manufacturer- and market-independent supplier we are able to provide clients with the best advice and put ideas into practice. Of course, our complete solution package includes also control engineering, electrical engineering, PLC-programming, assembly and after-sales service. This way, everything fits together perfectly ensuring a faultless, smooth material flow from the beginning to the end.
Important aspect: Despite sensitive technology the components must be rugged and reliably perform their duties in daily operation – if needed 24 hours a day. Conveyors by Klinkhammer – from one source and perfectly matching the requirements.
Order picking technology
In many warehouses, compiling different articles is one of the most labour- and cost-intensive processes. The correct selection of a modern order picking system allows each order to be processed more quickly and effectively. The specialists of the Klinkhammer Group will be pleased to assist you in finding out the ideal order picking strategy for you to save time and costs.
Order picking methods
- Pick-by-scan (barcode)
- Mobile acquisition: Handheld / tablet / PDA
- Stacker control system
- Wireless data systems
- Picking slips
- Palletizing and depalletizing by means of handling devices and robots
- Sequencing buffer to form the order picking sequence
For controlling the conveyors, the technicians of the Klinkhammer Group rely on the freely programmable technology of the Siemens S7 generation with TIA portal S7. This technology guarantees a service life of around 30 years. The availability of PC-components is not able to keep up with this.
Conveyor controller system
The conveyor controller system processes transport orders from the higher-level material flow computer, but also incorporates functions allowing stand-alone operation. Before commissioning at the customer site, the software generated specifically for the system is tested with test software at the premises of Klinkhammer. The system is operated and monitored using the ConVis visualization system. In manual mode, system interventions are made via stationary or mobile panels.
For a wide variety of AS/RS-types and loading/storage aids (pallets, containers, cardboard boxes, long items and goods with special dimensions) we developed standards. All AS/RS-types have one thing in common - a material saving travel control. The following options are available on demand:
- Energy-saving technology tailored to the corresponding device
- Variable acceleration and speed preselection
- As and when required, precision shelf positioning option for drive and lift axis
- Optical or data check of storage location occupancy in the AS/RS-control system
Materials Handling - Making Sure that Everything Runs Smoothly.
To ensure a convincing performance of a logistic solution and to work profitably, the system must be continuously maintained, refined and adapted. Our Service24 team provides a sound basis for a reliable operation with a full service throughout the whole year, plans inspections and trains your employees to ensure perfect functioning of all processes.
Hotline - 24/7 - +49 911 93064 574
In case of a technical problem or malfunction of your system our Service24 hotline is the address to get directly in contact with one of our highly qualified service technicians, 7 days a week, 24 hours a day.
Your questions are answered promptly, diagnosis and troubleshooting occur online via remote access, if and where possible. The hotline is split into software, control technology and mechanical helpdesk. If a problem cannot be identified clearly, a central contact person is available for coordination. This way, our customers quickly find a competent contact person and a solution for their problem.
The hotline service is available to contract customers and non-contract customers - 7 days a week, 24 hours a day. Of course, we also come directly to your site. Our service vehicles are active around the clock, whenever a breakdown or standstill of your system occurs. By the way, our service team consists of Klinkhammer employees only and we use no external manpower.
Service Contract with On-Call Service
What’s the difference between hotline service and on-call service? By opting for the on-call service, you as customer secure – within the scope of a service contract at fixed costs - the highest service level for critical applications and thus ensure maximum system availability. Response time and arrival times on site are exactly defined. Thus, you can be sure that in case of a sudden system standstill our immediate support is activated and the problem is solved.
Within the scope of our on-call service, our Service24 team will be available 24/7, 365 days a year. At the agreed dates, within certain defined time quotas. Look forward to more reliability guaranteed by a reliable service and competent contact persons.
What applies to cars - “Germans’ favorite toy” - applies also to intralogistics systems. Maintenance is not an end in itself, but serves to maintain the value of the device and system availability. Maintenance is also an investment in the future of the system and secures the capital invested. Our Service24 keeps a very close watch on respecting maintenance intervals and has its own, specific test routines. Thus, discrepancies and errors will be recognized immediately at the beginning to remedy them in good time, even before they cause real damage.
Therefore the aims are obvious: Maximum service life, minimum downtimes and highest safety and reliability. Not to forget the following aspects belonging to maintenance as well. We take care of carrying out the prescribed, internal and legally required safety tests. This way, our qualified and skilled service staff ensures that any hazards are identified early and thus can be eliminated. Your benefit: as customer you can be a 100% sure that you have complied with legal regulations.
Spare Parts Supply
For many of us the problem is all too common: You are looking for a spare part for a system or device which is around five years old, but is still working properly. However, you cannot find it and thus have to sort it out. To ensure that this doesn’t happen to your intralogistics system, we take care of it by offering you our spare parts concept.
Within the scope of our Service24, we work out a customized spare parts package that reflects exactly the needs of your system. When working out the spare parts packages, we take into account properties such as economic feasibility, optimum system availability, procurement lead times and transport times. If the required spare parts are not available on site, we procure and deliver them quickly and reliably. A sophisticated, clever spare parts management helps to achieve optimum utilization of the storage area and to have only relevant spare parts in stock. This simplifies work and is good for your budget.
The best system cannot operate efficiently, if used improperly by the staff or if the staff does not know about the options the system offers. This is why training is an integral part of our Service24. Training helps to understand the contexts and to protect against damages caused by operator errors.
Practically oriented training units ensure that your staff is getting familiar with the system. In workshops we inform you about the potentials and specific features. In the end, your employees are professionals, qualified for handling the complete intralogistics solution of your company. You get to know the processes and sequences and will be able to solve some of the problems yourselves. This, as well, means more efficiency.
Warehouse Management Software and Material Flow Control - KlinkWARE®
KlinkWARE® is the new generation of logistics software for warehouse management developed by the Klinkhammer Group to meet the requirements of future-oriented material flow control. In terms of speed and intuitive operation KlinkWARE® is a pioneer in the field of lean touchscreen operation. For more than 15 years software of the Klinkhammer Group has been successfully used in more than 100 plants/systems. KlinkWARE® is based on up-to-date technology and software architecture.
As your reliable partner for warehouse management software with many years of experience we will give you advice which systems are most suitable for you. We understand your goals and your business processes and we provide you with customized and cost-effective solutions for your logistics processes.
So that your ERP can set the direction. A designation or name is more expressive than a number.
The article master, also called stock list, consists of many aspects a material or product requires when storing or handling it.
Bills of materials
Here, not only the components required can be specified, but also work steps including costs, allowed times or descriptive documents.
Customers / suppliers
Customer and supplier master data are maintained and updated jointly. The so-called account plays a privileged role. Thus, also freight forwarders among others have an account allowing them to analyse the supplier relationship.
There are not just shipping addresses or invoice addresses, but also sender addresses on behalf of your customer.
Receipt of Goods
Register your goods already at the gate right after unloading. Complaints can be documented promptly. Your sales department is given information about the immediate availability of the goods.
At a work station or RF terminal, the user is provided with information on notifications or orders and collects further information to complete the process.
An automated receipt of goods can be realized using scanners mounted to the conveyors or using RF-terminals. This requires information that come from the labelling of the respective goods in the form of bar codes (e.g. GS1) or RFID tags.
Place your fast movers so efficiently that they reach the shipping zone on the shortest route when being retrieved.
The dynamics of the storage and retrieval cranes and shuttles, their capacity and availability influence searching a storage location in the same way as the article distribution for bypassing a malfunction and the positioning based on the turnover rate.
Addition to existing stock
Same batch, same FIFO date, same properties - nothing is more inviting to save storage space and merge stocks.
Route optimization is possible with several trading units to be stored in combination with a retrieval operation: Employees are never empty-handed.
Trays & Co.
This is a sort of addition to an existing stock: Sub-trading units are created which are managed by means of a load handling attachment. A dissection or space management is possible.
Provide your storage zones with sufficient stock at any time such that this stock is available for your orders.
In case an order is received and released for which there is not sufficient stock in the requested area, a replenishment order is initiated dynamically. Without demand no replenishment is necessary.
Based on minimum quantities defined or a minimum number of storage units the system detects a material shortage and a replenishment transaction is triggered.
This module complements the demand-oriented replenishment for refilling the order picking zones at regular intervals. The waves reduce ad-hoc measures.
Delivery Order Management
The order management offers you complete control over all processes which are order and stock related, from order release, progress and quantity update all the way through to dispatch of goods - whether complete or partial deliveries.
Order release filter
Certain order types, shipment types, customer groups, destination countries, orders that exceed or fall below certain volumes, weights or a number of items or that contain certain articles or require special processing may be treated differently.
For optimizing shipment and packaging costs, it is possible to consolidate single orders to shipments. The generation of routes is possible as well provided that criteria exist for this.
The activation strategy defines if and when an order is really processed. The availability of work stations and capacities as well as meeting deadlines and priorities (e.g. express orders) or sequences are decisive here.
The backorder management module is necessary, when the ERP-System or inventory management system transmits orders to KlinkWARE® without checking the availability of the goods.
Upon request, strategies are applied which do not only take into account the FIFO principle, but which also consider aspects like quantity optimization, low number of accesses, the avoidance of opening a pack or the equal utilization of resources.
Integrate value-added services or special processing operations. The standard service takes place at service stations between order picking and packaging. But also complex processes are possible - up to the production of articles based on bills of material.
A manual "simple service" in KlinkWARE® is the display of certain jobs or activities at the service station where the user only needs to confirm the fulfilment of these tasks or jobs.
Service during the order picking process
In case a service shall take place during order picking, no service work station is required e.g. for labelling goods using a mobile printer.
This module represents among other things the formation of sets or the display rack construction. If an order includes sales-type bills of materials that must be linked physically to a product, this happens in the "production service" module. This module enables providing more information up to work steps that ensure a high quality of the result on the one hand and allow logging the process on the other hand.
An automated procedure e.g. may be labelling with an applicator or the processing at a production line.
Service in the packing process
Using this module, you have all things together to prepare the goods for dispatch in a customized way.
By means of the "shipping scan" your packages leave the warehouse at the dispatch gate. Everything is under control - whether at the ramp or on the truck.
Manual shipping is ensured by mobile end devices that are equipped with the necessary reading units such as bar code scanners or RFID-reading units. The user receives information about shipping, verifies and acknowledges the process. Loading sequences are communicated via dialogues.
The automated shipping is ensured through conveyor scanners or mobile end devices without further interventions being necessary. Loading sequences were already taken into account by the system in advance.
Optimize the routing concept and paths and benefit from consolidated transports. The software module defines automatically which device is responsible for which route section and which optimization principle is used.
Manual - Goods-to-Man
In manual systems, too, Goods-to-Man procedures can be applied. Hence, narrow forklift trucks should also perform double cycles; however, aisle changes must be reduced.
Manual - Man-to-Goods
Typical Man-to-Goods applications have a great need for optimization. Not only routes are optimized, but also consolidated transports are created that include more than one container/box or order to allow multiple retrievals or to combine storage and picking/retrieval transactions.
The communication module takes the responsibility for the telegram exchange with the system controllers. Status messages, transport orders and their completion notifications are exchanged reliably.
The conveyor controller acts and reacts while communicating with the conveyor PLC. This module is in charge of managing the reporting points and integrating scanners and other devices. The routing controls the degree of utilization and the availability. By means of additionally programmed functions this module allows also integrating actions not being related to transport such as the automatic labelling, automatic goods receiving or shipping.
Interfaces, Integration & Adaptation
As modern, modularly structured software KlinkWARE® integrates into existing system landscapes and offers an interconnection to shipping and special systems.
- Bills of materials
- Customers / suppliers
- Orders / incoming goods notification
- Delivery orders
- QA orders
- Inventory orders
- Feedback to all procedures
In case a partner system should not use our native interface, we use KlinkWARE®-WRX - our communications module which is able to handle various formats and procedures.
When receiving messages, the interface converters make your format to become ours and when sending, we make our format to become yours.
Adaptation to your needs
To customize standard procedures it is often necessary to make modifications. Here, we always take particular care to maintain full compatibility with the standard so as not to jeopardize release capability and maintainability.
Although the technologies use the same logistic processes, they feature different options to present them to the outside.
Processing based on papers
Even though it might appear completely far-fetched in the electronics age to work with lists, there are, however, practical reasons to opt for paper-based solutions. Examples to state here are the operation of an external store without digital infrastructure or an emergency plan in case the wireless network fails.
Processing with handheld RF devices
Handheld RF-terminals are rugged and versatile warehouse companions. They offer the possibility of covering almost all logistical processes. These terminals, however, are limited as to their display possibilities. This is not necessarily a disadvantage. Terminals focus on the corresponding process and give clear instructions.
Mobile web browser applications
Browser applications mainly serve information and administration purposes. They are platform-independent, can be reached while away from the office, are easy to operate and intuitive. Printing even of bar codes is possible just like that. But also processing modules are operated remotely when no work station application is necessary.
Our Experience for Your Success - Faster processes, easy touch operation
Speed - up to 5 times faster
Thanks to the state-of-the-art technology and software architecture the processing speed of the control jobs in form of PLC-telegrams is up to five times faster than in the system existing so far. In tests with 4 PLC-controllers around 50 telegrams per second and PLC could be received and replied just as quickly. This corresponds to a through put of 400 telegrams received and sent per second. Thanks to the in-memory database technology being used for quickly processing statistical analyses, data exchange and archive functions an object-oriented database is used in addition to a conventional, relational database. This guarantees a high system performance.
Excellence in Touch - more mobile
KlinkWARE® is a pioneer in the field of lean touch screen operation of panels,
tablets and forklift truck terminals. The slide function avoids laborious and
extensive scrolling. By quickly brushing the surface with the fingertip it is
possible to easily navigate through lists, by tapping the relevant functions
zoom in and using the one-page function overall view or partial views appear
with one single touch. The lean and easy to use software thus considerably
facilitates the handling for the user and saves time.
No matter whether we are talking about a high-bay warehouse, an automated small-parts store or about building a new center of distribution - Klinkhammer supplies you upon request with a ready to use system solution. As general contractor for all technical areas to be integrated or e.g. especially for the intralogistics components, Klinkhammer takes care of on-schedule commissioning and handover of the project to the customer.
This means for our customers: One contact person for all issues - which means less time spent on coordination in the company. We think and act in your interests and represent you externally without sacrificing the transparency you expect. Continuous information transfer and full involvement are guaranteed. By appointing a general contractor, you as customer have the possibility to hand over the planning-sensitive and most risky services to a specialist at relatively low investment costs.
Of course, it is good, if we as general contractor are involved in the planning process as early as possible,because then we know the higher-level intralogistics goals and are aware of the special requirements. Ideally, we are already in charge of consulting, analysis and planning. This ensures that no breaches occur and consistency is guaranteed such that the holistic 360°appraoch – characteristic for Klinkhammer – takes effect with all its benefits:
- Theory and practice in harmony
- Low consulting and coordination needs
- One contact person for all steps
- Transparency across all project phases
- Overall solution from one source
- Savings of possible adaptation costs incurred between planning and implementation
A precise calculation considering all contemplable parameters, absolutely transparent calculations and communications focused on transparency with our customers, these are our most effective tools. The result: highly efficient processes that cover the flow of materials, productivity and just-in-time management in all areas at the best.
Logistics planning - Standardized processes
Here, we do anything but reinventing the wheel for each customer in logistics planning. Despite all individuality a new challenge demands, the processes to find a solution are always quite similar. The key to success in particular consists in adhering strictly to the well-established steps. When newly developing a logistics planning we therefore run through the same steps to be able to present our customers the optimum overall solution at the end of the day.
Data Acquisition - On-Site-Recording
Planning starts with a close dialogue with our customers during which we determine the requirements to the logistics system.
This is why a clear and comprehensive analysis of the data and looking at the future (target data) is of such importance. So it’s good to know that the Klinkhammer Group can rely on many years of experience and the know-how gathered in various projects.
- Construction, furniture, logistics and fire prevention
- Stored goods, fire classifications
- Loading units
- Goods in stock, i.e. articles and quantities
- Flows of materials
- Warehouse functions and tasks
- IT and organization
During analysis, our specialists have a look at different raw data, for example:
- Article master data
- Order data
- Incoming goods data
- Returned goods and
- Stock data
- Batches and expiry dates
- Delivery times
The more differentiated the data looked at, the more precise are analysis and the project planning resulting thereof.
The material flow planning and the system layout help optimize and visualize space consumption, minimize throughput times and point out efficient flows of material.
System layout and material flow
- Warehouse types with capacity
- Automated warehouse control concepts with goods-in and goods-out performance according to the FEM9.851 directive
- Conveyors and material flow computer
- Buffer capacities
- Work stations (incoming goods, order picking, dispatch preparation)
- Load diagram for floor plates
- Load calculation for ceiling suspensions
- Determination of wall breakthroughs
- Fire protection (sprinkler systems, inertization, etc.)
The first automated warehouses date back to the early sixties. Changing business needs, changing market requirements, updated safety and regulatory standards and constantly evolving technology - all this does not inevitably has to lead to an investment in an entirely new system or installation. In this respect, it is irrelevant who supplied the old system. When planning the retrofit of an existing installation no aspects will be omitted.
- Capturing the problem and analysing the system on site
- Working out a retrofit concept
- Replacing outdated computer and control systems
- Exchanging control and bus systems
- Updating safety systems
- Optimizing performance
- Restructuring of systems
- Checking the availability of spare parts
- Updating the system documentation
- Professional and experienced project management and implementation planning
- Professional service and maintenance
- Increase in productivity, performance, profitability and efficiency
- Ensuring the availability by replacing outdated components
- Reduction of maintenance costs by using more energy-efficient drives
- Energy saving thanks to modern energy management
- Enhanced communication of material flow control and warehouse management software
- Complete and consistent processing by one provider
- Step-by-step execution of renovation and upgrading activities during operation
- Optimal care and support by our Service24 team
- Reduced maintenance costs