Pesmel’s customized automated sorting buffer is connected to Mondi’s new 210,000 metric ton per annum kraft paper production line in Štětí, Czech Republic.
Purpose in every step
“Every warehouse has its own purpose. In the case of Mondi Štětí, it is not to store but to organize,” says Jani Matikainen, Sales Manager at Pesmel.
The new production line is intended to meet growing demand for paper-based, flexible packaging and has started up production in December 2024. The system supplied by Pesmel includes an automated roll warehouse (ARW) with a 3,000 metric-ton capacity for buffering sack kraft paper rolls. The incoming roll flow is first pre-sorted on sorting channels, from where stacker cranes pick-up and store rolls on storing channels. This two-step flow ensures high flexibility, along with full redundancy and re-routing capabilities.
“Daily production is about 600 tons per day, so with five days’ worth of storage this has a shorter turnover rate compared to some facilities we have worked on,” continues Matikainen, “and it fills a need that would be almost impossible to meet manually or with other alternatives within such a limited space.”
A 32-meter-high deep-lane rack warehouse serves as shipment storage, operated by two stacker cranes enable a high storage density crucial in an area with limited space but with very high roll flow. Rolls with different characteristics are constantly produced, so the ARW must organize inventory SKUs (Stock Keeping Unit) according to product type, receiving them in random order and send them out as required.
Dispatch loads are automatically retrieved from the warehouse and transported to the loading area via two outfeed lines. The dispatch area is designed for both efficiency and flexibility, allowing simultaneous loading of trucks and trains. “Traditional clamping can damage the products,” Matikainen explains. “In this system, rolls only needs clamping once as they are loaded onto transport. This essentially eliminates ‘broke’ from the equation.”
Adaption and customization are key
Pesmel’s proprietary Warehouse Management System (WMS) ensures fluid and optimized operation by controlling the warehouse, pre-sorting and dispatching functions, enabling inventory management, product identification and product traceability.
“This kind of rack storage solution was a new idea to us, and we were bit skeptical at first,” admits Helmut Riesenberger, Mondi’s senior project manager, “but the benefits it offered compared to alternatives were overwhelming. We got interested – it would be perfect fit for our needs. The reference visit to see the Saica mill in El Burgo de Ebro, Spain finally convinced us. I have long relationship with Saica and when they gave us a strong recommendation, we were convinced.”
“This kind of rack storage solution was a new idea to us, and we were bit skeptical at first, but the benefits it offered compared to alternatives were overwhelming. We got interested – it would be perfect fit for our needs.
Helmut Riesenberger, Senior Project Manager, Mondi
The project confirms Pesmel’s ability to provide efficient, cost-effective solutions for storage, handling, sorting, or any combination. “Adapting and customizing Pesmel’s Material Flow How® concept is a key benefit that enables us to efficiently meet our customers’ needs,” Matikainen concludes.
For more information about the new state-of-the-art kraft paper production line at the Štětí mill, please watch the video: PM10 – YouTube.
More information
Kaj Fahllund
+358 20 7009 626
kaj.fahllund@pesmel.com