Lindab Automated Distribution Center

Project Overview

Lindab International AB, a leading company in the construction industry with over €800 million in annual revenue and more than 5,000 employees, provides high-quality products for simplified construction and improved indoor climate. To meet increasing customer demand for higher delivery service levels, the company's board of directors made the strategic decision to build a new automated distribution center.

The facility addresses a clear industry trend toward more frequent, accurate, and faster deliveries, with customers increasingly requiring partial deliveries on a just-in-time basis. The new distribution center spans 10,600 square meters total, with the automated high-bay storage facility occupying 4,900 square meters and built vertically to maximize storage volume in an area with limited land access.

After careful analysis of several options, Lindab selected Swisslog as the system integrator based on the company's extensive portfolio of outstanding reference projects and its ability to deliver a totally integrated solution. The project was completed rapidly, with installations beginning in February and the facility operational by late summer.

Technical Solution

Automated High-Bay Storage System

The core of the facility is an automated storage and retrieval system (AS/RS) with capacity for 21,500 pallet positions. The high-bay design maximizes vertical space utilization, critical for the site's limited land availability. The system is designed to handle 250 pallets inbound and 250 pallets outbound per hour, providing substantial throughput capacity.

Key Features

The 21,500 pallet storage capacity in just 4,900 square meters demonstrates exceptional space utilization through vertical high-bay construction. This density is critical for the site's limited land availability and provides substantial inventory holding capability.

The system's 250 pallets in and 250 pallets out per hour throughput capacity supports high-volume operations. This bidirectional capacity ensures the facility can simultaneously handle receiving and shipping activities without bottlenecks.

Three stacker cranes provide automated storage and retrieval with high reliability and speed. The multi-crane configuration offers operational redundancy and maintains productivity during maintenance windows.

The 16 dynamic picking stations enable parallel order processing with goods-to-person ergonomics. This configuration maximizes picking productivity while reducing operator fatigue compared to traditional pick-to-goods methods.

The ProMove conveyor system creates seamless material flow between all functional areas. The integrated conveyor network eliminates manual pallet handling and ensures consistent throughput.

Swisslog SynQ software integrated with Lindab's WMS provides comprehensive control and visibility. The data-driven operation optimizes all warehouse processes from receiving through shipping.

Next-day delivery capability for all stock items represents a significant service improvement. The automated system's speed and accuracy enable Lindab to meet aggressive delivery commitments.

The vertical construction approach maximizes storage volume in limited land area, aligning with sustainability goals by minimizing the facility's footprint and land consumption.

Results & Benefits

The facility achieved a remarkable 50% productivity improvement compared to the previous operation. This dramatic increase stems from automation eliminating manual travel time, optimizing picking sequences, and enabling continuous 24/7 operations.

The operation now processes 1,500 order lines per shift, demonstrating substantial throughput capacity. This volume supports Lindab's growing business while maintaining high service levels.

Daily pallet handling reaches 1,000 pallets, with the system managing both inbound receipts and outbound shipments efficiently. This throughput meets current demand while providing capacity for future growth.

Next-day delivery is now available for all stock items, a significant competitive advantage in the construction industry. The automated system's speed enables Lindab to receive orders later in the day while still meeting next-day commitments.

Picking quality increased substantially through the goods-to-person approach and system-directed picking. The elimination of travel and search time, combined with clear pick instructions at ergonomic stations, virtually eliminates picking errors.

Lead times for customer orders decreased significantly, improving customer satisfaction and enabling just-in-time delivery models. Customers can now order more frequently in smaller quantities, reducing their inventory carrying costs.

The overall solution aligns with Swisslog's Green Logistics concepts and Lindab's sustainability tagline "Good Thinking." The vertical construction minimizes land use, while the automated system optimizes energy efficiency compared to traditional warehousing with extensive forklift operations.

Challenges & Solutions

The primary challenge was limited land availability at the site, requiring maximum storage density within a constrained footprint. Lindab and Swisslog addressed this by building the high-bay storage facility vertically, reaching substantial heights to accommodate 21,500 pallet positions in just 4,900 square meters. This vertical approach maximized storage volume while minimizing land consumption, aligning with both operational and sustainability objectives.

Another significant challenge was meeting increasing customer demand for more frequent, accurate, and faster deliveries, often with partial shipments arriving on a just-in-time basis. The solution combined a fully automated AS/RS with 16 dynamic picking stations and integrated warehouse management software. This configuration enables rapid order processing with high accuracy, supporting next-day delivery for all stock items and flexible partial shipment capabilities. The automation handles 1,500 order lines per shift, meeting current demand while providing capacity for future growth.

System Integrator

Swisslog provided the complete turnkey solution, including all warehouse equipment: the automated high-bay storage facility with 21,500 pallet positions, three stacker cranes, 16 dynamic picking stations, and the ProMove conveyor system. Swisslog's scope also included the SynQ warehouse control software and its integration with Lindab's existing WMS.

The project demonstrated Swisslog's expertise in delivering integrated automation solutions. Installations began in February, and by late summer the facility was operational—a rapid timeline for a project of this complexity. While minor challenges arose during volume ramp-up, Swisslog and Lindab worked collaboratively to quickly resolve any issues.

Swisslog continues to provide ongoing service and support to ensure stable operations for the foreseeable future, demonstrating their commitment to long-term customer success beyond initial installation and commissioning.