Mobile Robots Close the Loop Between Warehouse and Production at Pöppelmann

At Pöppelmann GmbH & Co. KG, a leading manufacturer in the plastics processing industry, material transport was previously handled manually. To meet growing demands and boost efficiency, the company has now implemented mobile robots from SAFELOG. These automated vehicles manage the entire transport of load carriers within the K-TECH division, relieving employees and optimizing production workflows.

Pöppelmann: A Pioneer in Circular Economy and Digitalization

Headquartered in Lohne, Germany, Pöppelmann employs nearly 2,500 people across six production sites operating around 700 plastic processing machines. The company serves various sectors including automotive, electrical, food, medical, and horticultural industries. Through its PÖPPELMANN blue initiative, the company has positioned itself as a pioneer in the circular economy, aiming to conserve resources and protect the climate.

Redesigning Processes in the K-TECH Division

As part of the Pöppelmann digital initiative, departments are regularly analyzed to identify efficiency potential. In the K-TECH division, which produces high-quality injection-molded parts for the automotive and industrial sectors, continuous material supply is essential. Previously, a tugger train system transported empty and filled containers manually — a loud, physically demanding, and inflexible process.

Motivation for Automation

“The tugger trains caused significant noise and required heavy manual labor,” says Michael Czwaluk, Logistics Team Leader at Pöppelmann. The goal was to find a system that would both reduce physical strain and improve flexibility. After evaluating 20 potential automation partners, SAFELOG was selected for its technology and cost-performance ratio.

Compact and Agile: The SAFELOG M4 Lift

Pöppelmann chose the SAFELOG M4 lift, a compact and highly maneuverable mobile robot ideal for narrow production aisles. The M4 lift can drive underneath floor rollers, lift them, and transport them to the required destinations. With a turning radius of just one meter and a maximum payload of 1,000 kg, the robots can easily handle Pöppelmann’s load carriers weighing up to 600 kg plus roller weight.

Seamless Integration During Operation

Eight mobile robots are now in operation, with a ninth serving as backup. The fleet autonomously moves empty containers to production machines, collects filled ones, and returns them to the warehouse, completing a closed supply loop. Implementation took place during ongoing operations, with each robot being gradually integrated into the system.

Navigation and Safety

The robots navigate using digital maps of the production halls, referencing static contour points such as pillars and machines. This eliminates the need for magnetic tracks. Operating in mixed traffic, the robots are equipped with safety sensors that slow or stop movement when obstacles are detected, ensuring safe interaction with forklifts and employees.

Decentralized Control for Reliability

SAFELOG uses an agent-based control system — each robot operates autonomously with its own computing unit and communicates with others to coordinate tasks. This decentralized approach ensures reliability: if one robot fails, the others automatically take over its tasks without downtime.

Looking Ahead

The collaboration between Pöppelmann and SAFELOG has been highly professional and forward-looking. Future projects include the automation of downstream logistics processes, such as pallet handling and integration with conveyor systems. SAFELOG will again play a central role in these upcoming automation initiatives.

For more information, please visit: https://www.safelog.de/en/

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