Bergzeit GmbH

Shuttle warehouse and order fulfillment for e-commerce

For more than 25 years, Bergzeit, based in Otterfing near Munich, has been one of the leading experts in mountain sports and outdoor activities. With an online shop and two stores, the company offers more than 40 000 articles from over 520 brands. Strong growth in the previous years had pushed the company to its limits in terms of space and shipping capacity. In its original warehouse, storage and picking took place manually on shelf racks.

In preparation for further business development, Bergzeit decided to modernise its intralogistics system by automating the processes in warehousing, order picking and returns management. Large items such as backpacks, tents and shoes would continue to be stored in a manual area.

psb intralogistics was awarded the contract for its system solution that is based on its patented Multi Access Warehouse. The key advantage of the flexibly expandable concept is that Bergzeit was able to respond economically to current requirements and to directly integrate additional intralogistics expansion options for further growth. Thanks to the tailored concept the limited space, which was available in a new building, could be utilised in the best possible way.

psb installed for Bergzeit a seven-aisle shuttle warehouse with more than 55 000 storage locations on 27 levels. The shuttle lifts for the 56 shuttles and the tote lifts integrated in the warehouse have two load handling devices each, which enables the warehouse to provide 2 400 totes per hour at the picking workstations. An additional row of internal lifts has already been considered and can be easily added at any time to increase the warehouse performance further.

Up to 18 different customer orders can be processed at each of the 13 multi-order picking workstations, which are arranged side by side on a platform. The high-performance conveyor system also connects other areas to the warehouse, such as goods receiving and returns processing. In the first expansion stage, the intralogistics solution can handle up to 1 000 parcels per hour.

Another factor in the decision to award the contract to psb was the sustainability of the installation. To conserve resources and save energy, all systems are equipped with supercapacitors and energy recovery modules. In addition, a large amount of the energy required is generated sustainably already during the production of the system installation.

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