MINDA as a full-service provider, including in-house storage and high-bay warehouse
Back in 2019, MINDA, as a full-service provider, implemented the complete intralogistics system at VPK Packaging in their new greenfield plant in Halden, Norway. Apart from the discharge from the corrugator, the project also included the integration of converting machines and the entire intralogistics up to the dispatch area, as well as in-house storage and high-bay warehouses.
The project exemplifies the strategic partnership between MINDA and VPK, which is based on trust and technical expertise. And the comprehensive system integration speaks for itself: continuous intralogistics without interface issues.
“The successful implementation in Halden is the result of a strong, trustful cooperation between VPK and MINDA. Together, we mastered challenges - such as difficult conditions during the pandemic - and created a system that seamlessly connects production and logistics. With the integration of our high-bay warehouse and in-house storage, this is a significant flagship project for MINDA, through which we have jointly set new standards for internal material handling,” confirms general project manager Benjamin Simmons (MINDA).
The development and results of the project are an impressive example of what can be achieved with a close partnership and a shared vision.
From corrugated board production up to the converting machines
Material is discharged from the corrugator via two stackers. The optionally rotated stacks are accumulated into blocks and thus assembled into optimized transfer car loads.
Most of the production output is temporarily stored in the In-house storage (IHS). The IHS features two aisles with four sets of shelves. On four storage levels, two storage and retrieval machines store over 600,000 square meters of corrugated board. Thanks to the IHS, VPK Halden can optimize its corrugated board output and thus plan production in advance, as the formats needed soon can be produced in advance.
Sheet plant delivery and semi-finished goods larger than 2.80 m that must be transported directly to the converting machines - as well as urgent orders - are moved to the downstream buffer warehouse by means of a transfer car.
The infeed and discharge systems to and from the six converting machines are individually adapted to the respective requirements of the machines. Here, for example, the ADVECTOR 3200 prefeeder from MINDA with its space-saving, lateral infeed is also in operation.
To further increase flexibility in the plant according to production requirements, the “Sheet and Return Line” near the converting machines combines various functions: sheet plant delivery up to 5 m wide can be directly discharged as finished products. The area is also used as a buffer line for the converting machines or as a buffer area prior to palletizing.
In the discharge section, a transfer car with four decks transports up to eight blocks simultaneously from the converting machines to the pallet securing line.
From storage in the high-bay warehouse to dispatch of finished goods
For dispatch, the finished goods are put on pallets using the pallet loading station BoP. When storing half-size Euro pallets into the high-bay warehouse, additional slave plates are required, which are positioned underneath the pallets. For this purpose, MINDA developed a concept that feeds these plates fully automatically from the high-bay warehouse under the stacks. In addition, the slave plates are automatically removed before dispatch – so they never leave the system.
After palletizing, cover plates, pallets, or cover sheets are automatically put on top of the goods for protection, depending on the requirements. In two packaging lines, the finished goods are then strapped and optionally wrapped, as well as fully automatically labeled by the labeling robot EMiL.
The stacks can now be transported directly to the dispatch area (sequencer) for truck loading or stored in the high-bay warehouse (HBW) via the infeed line.
The 42-meter high high-bay warehouse has five aisles. On the lower level, five storage and retrieval machines organize the storage and retrieval operations at approximately 21,000 storage positions. Thanks to the combination of telescopic and satellite technology, both small and large formats can be stored.
In the fifth aisle, in addition to consumables such as slave plates, empty pallets, and sheets, large formats measuring up to 3800 x 2400 mm can also be stored. These large formats are stored on up to 9 Euro pallets. For optimized dispatch, two stacks can be automatically stacked on top of each other after leaving the high-bay warehouse. This provides optimal use of the truck’s loading volume and significantly reduces loading time.
The truck load is organized according to the specifications of the route planning. A pallet inspection system completes the scope of delivery. Defect-free pallets are buffered in the high-bay warehouse and then transported to the pallet loading station BoP.
End-to-end control and visualization
The entire intralogistics system is controlled via the MINDA MoveIT control and visualization software, including MINDA’s Warehouse Management System (WMS). Thanks to real-time material flow tracking, VPK can identify every single stack in their plant at any time. This end-to-end transparency - without “black boxes” created by interfaces - ensures greater efficiency in scheduling, control, and analysis.
From initial planning to lifecycle support: MINDA as general contractor
As a specialist in internal material handling, MINDA is acting as the general contractor for this project, covering the entire intralogistics process from a single source. The customer benefits from a single contact person for the entire process chain and an intelligently optimized material flow that is perfectly tailored to the requirements on site.
MINDA positions themselves not only as a supplier but as a long-term partner even after the project is completed.
Already in the early planning phase of the new VPK plant, MINDA contributed its decades of expertise and played a key role in the overall design. This included determining the optimal building size and the best possible integration of the high-bay warehouse into the building structure.
Whether as an independent consulting partner or as a general contractor, MINDA supports its customers, such as VPK Halden, in developing a cost-effective and future-proof overall solution. The coordination with architects, subcontractors, and other stakeholders - including topics such as sprinkler systems - is also handled from a single source. This results in a continuous planning process that reliably integrates technical, structural, and process requirements.
Thus, MINDA supports their customers as a trusted partner in every stage of the process, from the initial planning phase up to comprehensive lifecycle support.
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