As part of the Constantia Flexibles Group, Constantia Teich is a leading company in the European flexible packaging industry. The world's largest manufacturer of yoghurt lids occupies a leading position in the market for packaging in the food, confectionery and pharmaceutical industries, while at the same time supplying the Group companies with aluminum foil as a primary material - rolled from 0.6 mm to the desired thickness of 5-160 µm. With the expansion of the rolling mill at the main plant in Pielachtal, Constantia Flexibles is promoting more sustainable, local aluminum production and at the same time strengthening the European supply chains. The Group also relies on state-of-the-art technology from European suppliers: As part of the €50 million total investment, Vollert's intralogistics specialists took over the third expansion stage of the existing high-bay warehouse (HBW) and extended it by 50 m to 150 m in total. The high-bay warehouse serves as intermediate storage for the aluminum coils weighing up to 13 t between the rolling processes and can accommodate both hot coils in annealing racks and coils on spools. This is made possible by a special hybrid holder on the lifting cage. The new stacker crane from Vollert, together with an existing machine, ensures storage and retrieval on seven levels. The high-bay warehouse has a total of 450 storage locations, which can be filled with both coils and returned empty coils.
Existing technology put through its paces
"The high-bay warehouse was originally built in 2008 by another manufacturer and has already been extended once," explains Bastian Binnig, Senior Sales Manager at Vollert. "However, this company is no longer represented on the market. We specialize in such cases and can also rework third-party systems and connect them to our systems. This also includes integrating the safety technology into the existing control system and the final testing and declaration of conformity." A task that requires special know-how, which Vollert's heavy-duty experts have acquired in several hundred high-bay warehouse projects over the last few decades.
Quadruple connection to rolling mill and cutting line
Overall, the extended high-bay warehouse at Constantia Teich has several connections to the rolling lines as well as additional exits and entrances to the cutting line. In addition to the steel construction and the control and safety technology, Vollert, as general contractor, also supplied two transfer cars for delivering and unloading the coils to the rolling and cutting lines, two systems for turning and lifting as well as two coil manipulators. After final rolling and cutting, the coils are sent for further processing, while the empty coils are returned to the HBW and stored by the storage and retrieval machines for the next rolling operations.
From the start of construction to commissioning, the Vollert team needed around twelve months to expand the high-bay warehouse. The expanded rolling mill was officially inaugurated in May 2025. This will enable Constantia Teich to increase its capacities, particularly in strategic growth areas such as coffee capsules, pharmaceutical and food packaging. The plant covers the entire value chain - from rolling and printing to the end product.
