Compact reach truck unlocks new storage capacity at PROTEKTORWERK

PROTEKTORWERK stores, picks and dispatches roof drainage products, such as plastic guttering and downspouts, from its distribution facility in Itzehoe. Headquartered in Gaggenau, Germany, the family-run company is one of Europe’s leading manufacturers of building profiles.

The challenge: Creating additional storage capacity within the existing space

In order to create additional storage capacity, PROTEKTORWERK decided to restructure part of its existing warehouse. The goal was to make more efficient use of the available space instead of simply expanding the building, so a new set of requirements for the internal material flow had to be accommodated.

The new rack area enables goods to be stored at heights of up to 6.15 metres, beyond the reach of the existing pallet stackers. A truck was therefore required that could safely store and retrieve pallets at this height while still offering the necessary residual load capacity.

However, the lifting height was only part of the challenge. Between the rack storage area and the order picking area, the transport route passes through a gateway with a restricted height. On top of that, the rack aisles are only 3.2 metres wide. Therefore, the new truck  had to be compact and manoeuvrable without compromising the required storage height.

The solution: Tailored to the site

PROTEKTORWERK opted for the STILL FXR 16C reach truck. Compact enough to work within the available space, the FXR 16C’s mast can also reach the required storage height.
Designed for single or two-shift operation, it features a fully integrated lithium-ion battery. As the truck is only used for a single shift in Itzehoe, no adjustments needed to be made for continuous high-performance operation.

“I deliberately chose not to recommend a truck with greater power reserves, because ultimately, the most important thing is what the customer actually needs. The FXR 16C meets the space restrictions and is suitable for single-shift operation in Itzehoe,” says STILL sales consultant David Lorenz.

The material flow is also clearly organised. Once a lorry has been unloaded, the FXR 16C prepares the pallets for onward transport.  It takes a small portion of the goods directly to the picking area, while the remaining goods (around 90 percent) are first stored as full pallets in the new rack area.

The FXR 16C then collects the pallets from here and delivers them to the picking area as required. The reach truck therefore handles both the transport of newly delivered goods and the ongoing provision of goods from the intermediate storage area.

The result: Increased capacity and faster transport

The FXR 16C enables PROTEKTORWERK to utilise the full potential of the new rack area. At the same time, the longer distances between goods receipt, intermediate storage and order picking can be covered more quickly than was previously possible with pedestrian-operated trucks. This streamlines processes and enables a higher turnover during a shift.

“After a short period of familiarisation, our operators now work very well with the FXR 16C. It is responsive to control, runs very quietly and enables faster transport over longer distances within the warehouse. Storage and retrieval have also become much easier,” says Bernd Waldow, head of logistics at the Itzehoe site.

The lithium-ion technology has also proven its worth in everyday use. The battery can be recharged as and when required, without having to be exchanged. There is also no need for the regular maintenance required by a conventional lead-acid battery, which makes the truck straightforward for staff to use.

Before purchasing the FXR 16C, the PROTEKTORWERK team had not researched battery technology in much detail. It was only once the truck was up and running that the benefits became apparent, and the company now knows that lithium-ion technology is a viable option for future truck procurement programmes.

Bernd Waldow is also delighted with the collaboration with STILL. The STILL sales team continues to provide support even after delivery, ensuring that any issues are resolved promptly. PROTEKTORWERK also works closely with the service technician responsible for the area, who can be on site at short notice if required.

The Itzehoe project shows that the choice of truck is not determined by the highest possible power output. The key factors are how well a truck is suited to the intended task, the building’s structure and the actual usage profile. The FXR 16C can reach the required storage height, pass through the existing gateway and speed up the transport of pallets within the warehouse.