Alnatura relies on REA Coding and Marking Solutions from REA LABEL

To keep up with the constant growth in logistics, the organic retailer built a new distribution center for organic food with 17,000 pallet spaces on an area of 20,800 square meters in Lorsch, Hesse, in 2010. in 2014, the site was expanded again to include the world's largest wooden high-bay warehouse. It offers space for 35,000 pallets on eight levels.

The site is a hive of activity: work is carried out in three shifts, six days a week, with up to 2,000 pallets leaving the center for trading partners every day. Only the marking with shipping information enables the correct, customer-specific allocation of all orders. Due to the large capacity and high speed, a fully automated coding and marking solution is required.

Decisive advantages

Alnatura commissioned the warehouse specialist Swisslog, which manages the distribution center as general contractor, with the implementation. The offers of several providers were verified, and finally the choice fell on pallet labeler systems from REA LABEL, which were developed especially for integration into logistics processes. REA LABEL impressed above all with its performance and flexibility, reports Matthias Lindner (Logistics Service Department). In particular, the flexible labeling of pallets at different heights and from two sides is what makes the supplied REA systems stand out.

Precision and efficiency

Three REA LABEL pallet labelers have been in operation at Alnatura's logistics center since spring 2014. All pallets are picked there and transported onwards on a conveyor line. The pallets, previously wrapped in stretch film, are then marked with a pallet label on the front and longitudinal site. The modern and robust application mechanism developed by REA ensures particularly precise labeling at different heights: The ProfiBus interface transmits the corresponding height information for each pallet from the conveyor system to the pallet labeler. With double-sided labeling, up to 120 pallets with 240 labels per hour can be printed and applied. Single-sided labeling and three-sided labeling on the front, long side and backside are also possible.

Simple operation

Parameters are entered and changed via an integrated terminal with an illuminated, high-contrast LCD plain text display. The user-friendly touch panel is easy to operate. Simple handling in daily operation is a high priority for Alnatura. Vario quick-change mandrels ensure uncomplicated, fast label changes. The interface programming for data communication enabled easy integration into the existing production environment and flexible connection to the ERP system from which the print data is taken.

Convenient integration

At REA, interfaces via TCP/IP, DP coupling and digital data exchange are just as much a matter of course as a large selection of print module manufacturers. Therefore, especially customer requirements can be realized. By using high-quality standard components and the freely programmable, integrated Siemens S7 controller, a flexible system has been created. The compact, modular design enables convenient integration into the existing production environment and fast configuration of the machine. In addition, the REA LABEL pallet labeler is also available in stainless steel on request and can be used in refrigerated and even deep-freeze applications (-24°C).

Everything from a single source

REA LABEL develops and produces all labeling systems in-house at the company headquarters in Mühltal, Hesse. A team of specialists in Halle/Westphalia designs customer-specific labeling solutions in close dialogue with the practitioners on site. In addition to the often very individual special machine construction, the Labeling Technology division also offers standard systems from its own development and production. The company offers turnkey solutions from a single source, including hardware and software. Customers therefore benefit from perfectly coordinated system solutions. The portfolio of in-house print and apply systems is supplemented by thermal transfer print modules from e.g. Novexx, CAB, Zebra and other suppliers. There is also a wide range of consumables such as labels and ribbons.

Tailor-made solution

Thanks to in-house development and production, individual applications can be realized, such as the integration of print dispensing systems or the combination of different marking products. For thermal transfer printers, for example, the ribbon, printer and label components have to be matched to each other. The specialists at REA LABEL can sample the ideal combination of materials and verify the code quality with measuring devices from REA VERIFIER. Flexible adaptation to a wide range of requirements is facilitated by the modular structure of the technologies. This means that every customer receives the right, individually tailored coding and marking solution.

Smooth operation

Alnatura appreciates the REA LABEL labeling systems as well-integrated, reliable components that ensure efficiency and process-reliable processes in the ultra-modern warehouse: "Perfection is a must for a logistics center of this size," emphasizes Alnatura Logistics Manager Matthias Lindner, who also praises the comprehensive service provided by REA LABEL. The company is currently in the design phase for a REA robot labeling solution, which offers decisive advantages in the area of marking partial pallets, among other things, thanks to the millimeter-precise application of labels. One thing is certain: Alnatura will continue to rely on technology from REA LABEL in the future.