Project report 06/2012 fresenius medical care



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PROJECT REPORT 06/2012

FRESENIUS MEDICAL CARE BIEBESHEIM/GERMANY 


THE CUSTOMER

Fresenius Medical Care is the 

world‘s largest integrated provider 

of products and services for indivi-

duals undergoing dialysis because 

of chronic kidney failure, a condition 

that affects more than 2,100,000 

individuals worldwide. 

Through its network of 2,898 dialysis 

clinics in North America, Europe, 

Asia, Latin America and Africa, 

Fresenius Medical Care provides 

dialysis treatment to 233,156 

patients around the globe. 

Fresenius Medical Care is also the 

world‘s leading provider of dialysis 

products such as hemodialysis 

machines, dialyzers and related dis- 

posable products. Fresenius Medical 

Care is listed on the Frankfurt Stock 

Exchange (FME, FME3) and the New 

York Stock Exchange (FMS, FMS/P). 

Manufacturing of hemodialysis machines

PROJECT REPORT 06/2012

In the face of dynamically growing flows 

of commodity Fresenius Medical Care 

started in the beginning of 2006 to im- 

plement a comprehensive intralogistics 

project – taking into account a further 

growth during the next 10 to 15 years.

The extrapolation resulted directly in the 

project of a high-bay warehouse. The 

management clearly gave precedence 

to a consequently designed automated 

new building with generous reserves near 

Biebesheim am Rhein rather than to the 

alternative of an extension of the two 

existing conventional distribution centers.

The investment company Alpha Industrial, 

specialized in the design of logistics 

buildings, gives its support to an inno-

vative solution: it’s the first time that in 

Germany an investor not only finances 



CUSTOMIZED FOR THE FIRST TENANT

TAILOR MADE FOR THIRD-PARTY USERS

Sustainable investment model on greenfield site

Due to a universal layout even disposable pallets 

can be stored in the high-bay warehouse.

and rents a building but he also finances 

and rents the appropriate technology. 

The plan will only work out for the 

investor if the building, after expiry of  

a commercial lease of 15 years, will be 

interesting also for new users. 

High-bay warehouse, conveyor techno-

logy and software will be designed to 

meet general purposes beyond the 

requirements of Fresenius concerning 

the layout as well as the details:  

generous height of pallets spaces, dual 

or triple storage systems, roller spacing 

of conveyors, hall bottom floor executed 

with sealed pans for storage of liquids 

leading to water pollution.

The sustainability clearly offsets the 

additional costs for the investor. Fresenius 

Medical Care on the other hand has the 

advantage of a reasonable monthly rent. 




FRESENIUS MEDICAL CARE BIEBESHEIM/GERMANY

98 % OF AVAILABILITY   

GUARANTEED FOR 15 YEARS

Storage and order picking of medical 

equipments and materials require an 

especially high degree of reliability.

In this context it was a logical conclusion 

that LTW was awarded in September 

2007 the contract as general contractor 

for intralogistics, including the con-

struction of a silo and installation of  

an automatic sprinkler system.

According to Rainer Reichelt, logistics 

planner, LTW was able to submit an 

interesting quotation. “This was pro-

bably due to the slender structures and 

the close connection to Doppelmayr 

during production, a company who 

impressed us by its high level when  

we visited the premises in Wolfurt.  

From the point of view technology,  

LTW convinced us by a robust rigid 

construction of the stacker cranes with 

simultaneous weight optimization.“ 

The ultimate criterion must be the  

availability for continuous operation. 

Jointly with Fresenius Medical Care, 

LTW elaborated an innovating full 

service concept: LTW guarantees a 98 % 

availability of the plant for the total 

rental term of 15 years. 

To this aim LTW implements in close co- 

operation with Fresenius a proper service 

team on site. All of five employees of 

LTW get acquainted with the plant right 

from the stage of assembling; at least 

two of them monitor continuously the 

operation and use the time for preven-

tive maintenance work in order to 

reduce maintenance to once per year. 

Rainer Reichelt:” We put our trust in 

LTW who negotiated very clearly  

and who went with us this new way 

without thousands of ifs and buts.”



MATERIAL FLOW

The new distribution center brings 

together the two present central ware-

houses with different target regions and 

order structures.

70 % of the articles are exported as full 

pallets into 140 countries. In Central 

Europe the majority of articles is shipped 

as collated orders to backup warehouses

hospitals and individual patients.

All in all, the full pallet handling is  

prevailing – the ideal prerequisite for a  

high automation level of all material 

flows including automated small parts 

storage and fully automated identifi- 

cation point with pallet stacking and 

staging system.

Following the expansion of the high-bay 

warehouse by three aisles in 2011, ten 

aisle-bound stacker cranes are operated 

in two shifts and permit approx. 6,400 

pallet movements per day. A possible 

third shift offers a generous capacity 

reserve.


Beside the mechanical equipment, LTW 

also delivers the PLC control system for 

all components and for the warehouse 

control unit with interface to the SAP-

based warehouse management. Such  

a solution from one hand proves itself 

especially regarding maintenance, 

troubleshooting and fault clearance.

On site, at least two LTW employees per shift 

assure a smooth running.



TAILOR MADE FOR THIRD-PARTY USERS


LTW Intralogistics GmbH

Austria


Achstrasse 53 

6922 Wolfurt 

T + 43 5574 6829 – 0 

F + 43 5574 6829 – 29 

office@LTW.at 

www.LTW.at



LTW Intralogistics GmbH

Germany


Max-Eyth-Strasse 30 

89171 Illerkirchberg

T + 49 7346 3084 

F + 49 7346 3083 

office@LTW.at 

www.LTW.at



LTW Intralogistics, Inc. 

USA 


3285 North George Street 

PO Box 0115 

Emigsville 

PA 17318 – 0115

T + 1 717 767 7210 

F + 1 717 326 1279 

office@LTWUSA.com 

www.LTWUSA.com

0620

12/E          directed by transfair



OUTLINE OF THE PROJECT 

HIGH-BAY WAREHOUSE (HBW)

>  Galvanized steel rack

> Rack supported storage system 

>  L x W x H: 154 x 74 x 38 m

>  10 rack lanes 

> Double deep 3-/2 storage

> Approx. 78,000 pallet spaces

> Maximum payload: 1,200 kg

> Air conditioning: + 15 °C to + 25 °C

Stacker cranes  

>  10 aisle-bound stacker cranes

> Driving speed: 240 m/min

> Driving acceleration: 0.4 m/s 

2

> Hoisting speed: 70 m/min



> Hoisting acceleration: 0.6 m/s 

2

>  Load handling device:  



telescopic fork double deep

CONVEYOR SYSTEM

On 2 levels with storage and retrieval 

points in hall 1 and hall 2

>  2 picking zones

>  2 labellers (vertically adjustable)

>  1 pallet wrapping machine

>  3 transfer carriages

>  4 vertical conveyors

>  Automatic identification point 

including inhouse pallet handling 



AUTOMATED SMALL PARTS 

STORAGE

>  L x W x H: 48 x 8 x 6 m

> 2 rack lanes 

> Double deep storage

>  Approx. 8,700 spaces for plastic  

boxes  (400 x 600 x 220)

> Maximum payload: 50 kg 

Stacker cranes  

> 2 aisle-bound stacker cranes

> Driving speed: 300 m/min

> Driving acceleration: 3 m/s 

2

> Hoisting speed: 180 m/min



> Hoisting acceleration: 3 m/s 

2

>  Load handling device: KTC with 



double-sided output system

SOFTWARE

>   Warehouse control unit for high-bay 

warehouse and automated small 

parts storage

>   Certified SAP interface for  

customized storage management

>   Availability indication

>   Emergency operation for goods 

retrieval to maintain delivery  

capacity


carbon neutral

natureOffice.com | AT-157-031164



print production


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