Intra-plant material flow has long been a critical success factor for modern aluminum plants. From incoming goods through production to shipping, thousands of metric tons of material must be moved safely, precisely, and cost-effectively every day. At the same time, demands for space efficiency, process reliability, and equipment availability are increasing. Efficient intralogistics processes determine how efficiently, flexibly, and cost-effectively aluminum can be produced and thus ultimately determine competitiveness.
For decades, Vollert has been developing automated heavy-duty intralogistics solutions that intelligently integrate all material flows. The portfolio ranges from automated high-bay, floor-level, and cantilever warehouses to stacker cranes, automatic and process cranes, as well as conveyor systems, autonomous moving robots (AMRs), and overarching material flow control. The goal is to make optimal use of warehouse capacity, shorten transport routes, and reliably automate production processes.
Case study Logan Aluminum: Automation in a new dimension
The current large-scale project for Logan Aluminum in Russellville (Kentucky, USA) demonstrates just how efficient modern intralogistics can be today. For one of North America’s leading aluminum rolling mills, Vollert is implementing a fully automated material flow system for aluminum coils that sets new standards in terms of storage capacity, handling capacity, and system scale.
The new mega high-bay warehouse serves as an interface between the rolling mills and features four inlets and outlets to the hot and cold rolling mills. Standing 42 meters tall and with a payload capacity of up to 30 metric tons, it houses the largest stacker crane ever built by Vollert. The connection to the hot rolling mill, located approximately 350 meters away, is provided by a driverless AMR. The coils are picked up directly from the Vollert shuttle by the AMR and delivered to the stacker crane. Three coil transport pallet trucks handle automated transport within the cold rolling area. A Vollert shuttle car with a shuttle lifting car handles the feeding to the cold rolling mill. The project impressively demonstrates how high storage density, maximum process reliability, and efficient material flows can be economically combined even with the heaviest material weights.
Compact coil storage for existing production sites
With a newly developed compact coil storage system, Vollert is also expanding its portfolio of solutions specifically for aluminum manufacturers who wish to increase their storage capacity within existing buildings. The innovative storage concept is based on a compact cantilever racking system in which aluminum coils are stacked two or three high. Storing and retrieving the coils is fully automated via a newly developed compact stacker crane designed specifically for this system.
This results in significantly higher storage capacities within the same floor space particularly in existing buildings or facilities with limited ceiling heights. Companies can continue to make efficient use of their existing infrastructure without having to create additional warehouse space.
Automated crane systems for modern extrusion plants
Another focus at ALUMINIUM 2026 is on automated and process cranes for the aluminum extrusion industry. They handle the automated transport of extruded profiles, tools, and production materials, ensuring a continuous flow of materials between the press, cooling, storage, and shipping. This synchronizes production processes, shortens lead times, and sustainably increases process reliability. Successful projects completed for HAI, Neuman Aluminium, and heroal, among others, demonstrate how these requirements can be implemented in practice. In these facilities, intelligent crane systems automate the internal material flow within the extrusion plant and ensure reliable transport of aluminum profiles between the individual production steps. The results are higher plant availability, reproducible processes, and efficient production logistics.
Interested trade visitors can meet with Vollert experts at booth 3C53 during ALUMINIUM 2026 in Düsseldorf to discuss current requirements and future automation concepts for aluminum plants.