References
Precast concrete production
References
Precast concrete production
References
Precast concrete production
References
Precast concrete production
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Tractors every minute

Finnish manufacturer Valtra relies on a clever intralogistics solution for coating tractors. It not only allows chassis weighing up to eight tons to be coated overhead, but also to be buffered in a closed circuit and guided around corners. Two chain pushers in combination with friction wheel drives are used for this purpose. The lean solution guarantees continuous production in automotive eight-minute cycles.

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Fully automated rolling mill diening with central coil flat storage at Gränges

In future, Gränges in Finspång, Sweden, will use a new flat storage facility with an automatic crane from Vollert to organize the entire supply and removal of the new aluminium production area. The warehouse serves as the central interface between the cold rolling mill, the slitter lines and the packaging. Vollert is developing the complete intralogistics system, including coil cooling, inductive transfer cars, an automated guided vehicle (AGV) as well as the control and warehouse management system, and integrating it into an existing hall.

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Josef Lehner invests in state-of-the art double-wall production

As a 2nd generation family business, the Austrian construction company Josef Lehner stands for sustainability and foresight. As part of the expansion of its capacities for larger construction projects, the company has now invested in a modern, partially automated double wall production facility at its headquarters in Amstetten.

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Remote-controlled rail loading in Finland

The seaport operators in Pori, Finland, rely on a radio-controlled shunting solution from Vollert for the rail loading of iron sulphate as bulk goods. A Tandem DER 150 shunting robot provides and moves freight trains weighing up to 2,000 tons. The coupling system is compatible with both Eastern and Central European systems.

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Sustainable room modules for social housing in France's metropolitan cities

The French construction company Muance, which was only founded in 2020, has set itself the goal of transforming residential construction in France in a sustainable way. The goal: to reduce the overall CO2 footprint by 60%. To achieve this, the company is relying on a new construction system based on industrially prefabricated room modules. This was developed with the aim of minimizing the ecological footprint and at the same time creating affordable living space for many people.

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A good plan: Modular retrofit for increased production

Ensinger, a specialist for high-performance plastics, is meeting its customers’ high demands with far-sightedness and future-oriented planning. With a view to future production increases, the manufacturer used a digital twin to analyze its production sequences for weaknesses and develop modular solutions together with retrofitting specialist Vollert, to be gradually integrated into the existing production until 2027. This provides planning safety for investment costs and guaranteed delivery capacity at any time.

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Emission-free loading of hollow-core slabs with road-rail vehicle

Austrian building company HABAU GROUP invested 11 million euros into expansion of its hollow-core slab production in its Perg factory site, increasing capacity by nearly 30% per annum. Just like the entire preliminary planning of their new plant technology, loading and removal processes also rely on sustainable technology, such as an emission-free road-rail vehicle.

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Automated train loading at ŠKODA with Vollert train handlers

Two automated Vollert loading cranes ensure quick unloading of vehicle batteries for e-car production from trains at ŠKODA’s headquarters in Czech Mladá Boleslav. Automation reduces lading times while increasing safety in handling of sensitive batteries.

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Painting in breath-taking heights

Vollert developed a particularly space-efficient paint shop on two levels for machine and plant constructor KraussMaffei. The workpieces are moving on a crane track at a height of twelve metres. The walk-on painting and working area for the workers is located six metres high on the first floor, and the space underneath can be fully used – protected by a rock-solid fall protection for large parts with weights of up to 30 tons.

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Bernegger Group once again acting as a pioneer with Austria’s first energy-neutral precast concrete factory

Bernegger Group has a tradition of always thinking one step ahead – be it in the raw materials industry, the construction industry, or in environmental technology. The same is true as it enters the precast concrete industry. Since May 2022, double walls and prefabricated ceiling slabs for residential and commercial construction have been produced perfectly energy-neutrally in Dietach, Upper Austria.

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Kitchen countertops just-in-time

SWISS KRONO is accelerating picking for innovative countertops and melamine-coated wood panels for furniture production and interior fittings with a heavy-duty high-bay warehouse by Vollert. All wood formats required for picking will be provided in only two minutes.

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Economically producing aesthetic L-bricks

Stones, walls, and paving systems with high aesthetic value make landscaping distinctive for use in house and garden or in modern urban and commercial construction alike. Many building material manufacturers are already offering a high-quality and diverse range of concrete blocks. Formwork systems afford an interesting alternative for the production of L-bricks.

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UNGLEHRT automates precast concrete production

Whether concrete products for gardening and landscaping or walls, beams and columns - the traditional company UNGLEHRT has been producing high-quality concrete parts for more than 100 years and also specializes in turnkey commercial and industrial construction. In order to further increase competitiveness and also to have answers to the increasing shortage of skilled manpower, the company has now invested in an automation of the existing precast concrete parts production at the plant location in Bad Grönenbach, Bavaria.

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Soriba manufactures concrete stairs - optimized in terms of time, cost and CO2

Instead of stationary stair formwork, the French building materials manufacturer Soriba is relying for the first time on a rationalized and automated staircase production in a circulation-based manufacturing process. Movable side rails makes this possible despite the high diversity of stair variants. A new type of rotating-turning operation also brings considerable savings in steel and concrete consumption. The entire manufacturing process is thus optimized in terms of time, costs and CO2.

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Automated from coil to fully recyclable aluminum packaging

Vollert designed a fully automated intralogistics system for the flexible packaging specialist Aluflexpack (AFP) in their production plant in Drniš near Split in Croatia. In addition to a high-bay warehouse with a special treatment zone, the material flow concept for several hundred coils includes the complete automated transport of the very heavy aluminum coils of different lengths and diameters.

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Road-Rail Robot VLEX at Fret SNCF in the French Alps

Shunting expert Vollert deploys its VLEX robot vehicle for rail and road at Fret SNCF's maintenance site in Modane. The compact road-rail robot moves locomotives weighing up to 120 tons effortlessly into their maintenance boxes.

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Scrap Transport with Smart Road-Rail Solution

Heavy masses and efficient bulk material loading without endangering people – the transport of scrap and metal presents many challenges. The shunting specialists from Vollert meet this requirement with the robustly designed shunting vehicle for road and rail. VLEX 40 and VLEX 20, the compact product lines equipped with articulated steering are used at ESF Elbe-Stahlwerke Feralpi GmbH in Riesa and at VDM Metals in Unna.

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Grupo Avintia industrializes at high speed Spain's construction sector

In the Iberian Peninsula, the share of industrial construction is less than 1%, compared to 45% in Central and Northern Europe in 2020. Against this background, Grupo Avintia, one of Spain's leading developers, has developed ÁVIT-A, an integral, industrialized construction system. Climate neutrality in the building process and sustainability in the housing sector are decisive milestones in 21st century.

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Planchers Fabre expands beam production

Planchers Fabre, a subsidiary of the Rector Lesage Group, produces a wide range of beam and wall elements for the construction industry. In Pibrac in the southwest of France near Toulouse, the company has now expanded its industrial prefabrication for higher plant production capacities due to increasing demand.

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Easy ballast coating at Liebherr

At the Liebherr plant in Ehingen, Vollert planned and built a new ballast painting plant with friction wheel and rope conveyor technology for the coating of crane ballast elements. These are used as counterweights for mobile lattice boom and telescopic cranes with lifting heights of up to 245 m. Depending on the product carrier, elements weighing up to 20 tons can be coated in an overhead, suspended manner. A total of 25 product carriers are in circulation.

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Intralogistics made fit - without production downtime

A new stacker crane for 11-ton aluminum coils and a modern automatic crane system for extruded profiles have been speeding up the production processes of Hydro Aluminium Rolled Products and Neuman Aluminium since the beginning of the year. For the replacement of the central conveyor systems, two Vollert teams took advantage of the short production-free period over Christmas. With foresighted planning, they mastered the complex tasks even in the tightest of spaces and under tightened pandemic conditions.

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Kerkstoel 2000+ produces architectural precast concrete elements for high demands

Kerkstoel 2000+ and Vollert in cooperation with Prilhofer Consulting are currently setting a highlight in the industrial series production of architecturally sophisticated precast concrete parts in Belgium. Various precast concrete elements of the Kerkstoel Group can be found in modern residential and office complexes, but also in shopping centres, railway stations and airports. In order to continue setting trends, the Belgian building materials specialist invested in a new production plant for solid, double and sandwich walls in Grobbendonk for versatile component geometries and customer designs. This allows concrete elements with very different degrees of complexity to be produced in the same period of time without reducing plant productivity.

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Road-rail Robot VLEX now up to 600 t tensile load

With a new model of the road-rail robot VLEX, Vollert extends its compact solution to shunting operations up to 600 tons. Twice as strong, but only 500 mm larger, the new VLEX 40 is also suitable for fast track changes in confined spaces. A swing axle guarantees permanent ground or rail contact of all four wheels, even on uneven ground. And thanks to the emission-free electric drive, operation in closed storage and production areas is also possible. The extremely maneuverable shunting solution of the VLEX 20 is used, for example, in the South Korean metro in Seoul, for moving tank wagons at Lanxess in Leverkusen or for loading lime at Rheinkalk Grevenbrück GmbH.

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Fully automated cantilever warehouse for steel coils

At its headquarters in Hagen-Hohenlimburg, the BILSTEIN GROUP invested in a wide quarto reversing rolling mill and a new slitting line with a fully automated buffer store for steel coils with a width of up to 1,350 mm and a weight of up to 31 tonnes. For direct access, these are stored hanging from cantilevers. A fully automatic stacker crane from Vollert ensures smooth storage and retrieval.

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Vollert brings paint shop from Arburg to a high gloss

In a comprehensive retrofit project, the intralogistics specialists from Vollert modernized the complete conveyor technology of an existing large parts painting plant for the injection moulding machine manufacturer Arburg. While retaining the existing crane runway and painting technology, the processes were accelerated, the painting processes improved and automated and extended parts of the plant technology were added.

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Automatic, fully hydraulic, efficient: Hungarian Limelog Group expands stationary production of precast concrete parts

Since 2009, the Hungarian Limelog Group has specialised in the transport of high-quality building materials, grain and oversized machines and precast concrete parts inside and outside of Hungary. Since 2011, the company has also been extremely successful in producing reinforced concrete columns and beams. With KOMBISTEP stair formwork and high-performance tilting tables from Vollert's special portfolio, the company is now expanding its stationary precast concrete production.

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Environmentally friendly coal loading at the new terminal in Riga

New terminals on the island of Krievu in Latvia form the modern infrastructure for loading coal in the port of Riga. Vollert supplied a DER 100 shunting robot to the terminal operator SIA STREK.

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Fourth sheet metal blanks high-bay warehouse for automobile production

Vollert erects a new material flow system with high-bay warehouse. It is already the fourth warehouse of the intralogistics specialist at the Mercedes-Benz press shop in Bremen. At the same time, Vollert increased the overall speed of the existing intralogistics processes.

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Just-in-time precast floor slabs for the Belgian housing industry

The Belgian building materials specialist Daerden is expanding its capacity in the production of serially prefabricated semi-finished concrete parts. Just-in-time within 24 hours, it will in future be possible to supply its customers in the booming Belgian housing industry with floor slabs. Automated processes and Vollert technology make this possible.

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Loading gravel fully automatically and environmentally friendly

In the quarry of the French building materials specialist Eqiom in the Bar-sur-Aube district, an energy-efficient fully automatic loading station ensures economical processes. For loading gravel, the wagons are constantly pulled through the filling station by an electrically operated KR 100 shunting robot.

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Aluminium profiles for e-mobility in highest quality

Hammerer Aluminium Industries (HAI) is investing in a high-end production line at its Austrian site in Ranshofen. The aim is to produce aluminium profiles of the highest quality for the future topic of e-mobility. With an automatic crane and a fully automated buffer store, the SPS Group and Vollert ensure damage-free material flow between the existing and extended production lines. From planning to commissioning, the intralogistics specialists needed only 12 months.

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Modular bathrooms efficiently and variable produced

Finnish building materials specialist Rakenusbetoni- ja Elementti expands its capacities in production of serially pre-fabricated bathroom modules. High-performance room mould by concrete specialist Vollert ensure high-quality surfaces and watertight room cells. The bathroom installation takes place very quickly, since the electrical and sanitary devices are already pre-installed.

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Please blast, dip, powder a 100 times

Truck trailers are useful, but also big and heavy. This does not make their transport in the paint shop easy. Giga Coating GmbH recently built a completely new surface treatment plant in Twist. Here, up to 15.7 m long and 9 t heavy large parts are not only coated, but also blasted, dipped, swiveled and heat treated in hanging furnaces. The automated circulation principle creates capacities for up to 100 trailers and special parts per day in two construction stages.

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The Oschatz concrete plant relies on robot technology

Forms, colours and surfaces become more and more modern; architecture turns increasingly diverse. At the same time, the capacities needed for building projects increase and the cost pressure is rising. The machine technology in precast concrete production must follow this trend. Modernisation is key in the Oschatz concrete plant.

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Hot furnaces, cool mechanical handling

For its new factory, Benninghoven, specialists in the construction of asphalt mixing plants up to 50 m in height and a member of the Wirtgen Group, is investing in a new double-track suspension system from Vollert for the overhead surface treatment of large parts. The special drive concept allows the overhead and flexible transport of up to 22 ton heavy parts, while at the same time enabling the energy-efficient separation of transport and furnace steel structures. Besides Benninghoven, in the company group Wirtgen and Kleemann are already using the proven Vollert technology.

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Tip and go: Loading by the cargo specialist Innofreight with shunting technology from Vollert

Innofreight Solutions GmbH from Austria has developed an innovative unloading station for the paper and packaging specialist, Mondi. As with voestalpine in Donawitz and at the Chvaletice power plant, Vollert's robust and energy-efficient shunting technology ensures reliable processes.

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Industrial pre-production of TERIVA floor beams and slabs in Poland

The Polish building materials manufacturer Uciechowski will in future be producing floor beams and slabs on an industrial scale using the TERIVA building system. Whereas manufacturing was previously purely stationary, it is now based on the latest technology of the concrete plant specialist Vollert. 50 shuttering pallets are transported in the circulation system, known up to now only in modern precast concrete plants.

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High speed production buffer for 3,000 tons of steel wire coils

Vollert erected for Saarstahl AG a new fully automatic high-bay warehouse for up to 665 steel wire coils at the Neunkirchen plant. In addition to the high cycle time of just 190 seconds per double cycle, the heavy-duty engineers also realized the handling of bundles weighing up to 4.5 tons directly from the stacker crane to the lift truck and on to the truck loading.

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Fast cranes for heavy loads

Neuman Aluminum modernized their material flows in the extrusion plant in Marktl, Austria, during the Christmas holidays. At the core is a new automatic crane system by Vollert with 21 interchangeable cycles for loads of up to 3 tons. It replaces two existing transport cranes and is one of the fastest automatic cranes ever used in the extrusion industry.

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Large-part painting systems designed around the corner

For LEWA as a special pump manufacturer and HAMM as a manufacturer of rollers for road construction and earthworks, Vollert developed and installed new floor-guided and overhead material flow systems for surface coating of parts weighing up to 12 tons. While high cycle times are crucial at HAMM, at LEWA for the first-time workpieces weighing tons travel 90° around the corner and thus enable an extremely compact system layout.

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bétons feidt creates special architecture in concrete

Precast architecture is modern and different. Numerous building projects worldwide prove that. It now has very little to do with standards and norms. One of the long-standing leaders among the manufacturers of such precast elements is the concrete specialist bétons feidt from Luxembourg. Vollert technology plays a big part in this.

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Compact with a smart steering

With the newly developed VLEX road-rail robot, Vollert offers the finest solution for light shunting operation up to 300 tons: Extremely compact and flexible, battery-driven and exhaust-free, the small VLEX is suitable to change tracks fast in a very confined space.

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Manufacturers of precast concrete elements increase product quality and system productivity through modernization investments

The system technology of many precast concrete element factories comes from the 1990s and is based on the standard of knowledge of the then relatively young field of prefabricated elements. Today, rising cost pressure and ever more versatile prefabricated element architecture with regard to forms, colors and surface qualities require new technology standards. The manufacturers of precast concrete elements are reacting to this demand and investing in machine technology and higher automation.

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A breath of fresh air for anode production

TRIMET Aluminium SE uses a new and so far unique in the world technique for the cooling of green anodes in its Hamburg factory: The pilot plant reduces the resource usage and dispenses with active cooling by water. Instead TRIMET relies on cooling by natural convection with outside air – and this with success.

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Belgian Cordeel Group becomes a key player of the European construction industry

Belgian Cordeel Group is a nationally leading construction company. The general contractor implements diverse building projects, from exclusive apartment facilities to logistics or industrial parks, modern shopping malls, hospitals, schools or infrastructure projects such as bridges. With the new precast concrete plant in Temse, Cordeel has finally become one of the large key players in Europe.

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Caution! Heavy load!

Low-loader manufacturer Faymonville dispatches components weighing up to 12 tons through its overhead painting plant in Luxembourg. The material flow concept also comes from a heavy load expert – from Vollert based in Weinsberg. The control system supports automatic operation as well as the manual transportation of parts. Friction wheels facilitate the space-saving plant layout.

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Vollert Exchanges twelve Stacker Cranes During Ongoing Automobile Production

For the retrofitting of a twelve-aisle fully automated high-bay warehouse at Mercedes-Benz in Sindelfingen, Vollert deliveres twelve stacker cranes, aisle equipment, conveyor equipment, safety, process control technology as well as electronics and the steel construction for the pre-zone. The exchange is made during on-going production over four construction phases. The existing storage system as well as the building itself remains unchanged.

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High-bay and automated intralogistics system speeds up production for Aleris

Aleris International, Inc. plans to boost production capacity in Duffel, Belgium with a new Sexto mill. To ensure smooth operation, Vollert Anlagenbau from Weinsberg will provide a fully-automated intralogistics system with high-bay warehouse. Up to 32 coils with a maximum unit weight of 25 tons are moved in and out of the warehouse each hour.

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Next stop: Paint center

In the new Siemens AG Austria coating center, metros and passenger carriages are automatically transported via a central transport system to the individual coating treatment booths. The transfer table allows for flexible arrangement of individual processing stations and offers the highest level of safety for crossing passenger traffic.

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Up and away – Continental exchanges 75 meters of test track in a matter of minutes

Anything but small, the exchangeable pavement cassettes used in the world's first fully climatized indoor tire testing facility from Continental weigh more than 100 tons and measure 75 meters in length. The facility allows the tire manufacturer to conduct 100,000 dry and wet brake tests per year using up to five different sections of test pavement. Vollert developed the system that quickly changes the cassettes.

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Fully automatic coil transport in Hydro aluminium mill

Hydro Aluminium Rolled Products GmbH has commissioned Vollert Anlagenbau to modernise its existing plant in Grevenbroich by designing an end-to-end intralogistics system that automatically loads and unloads lorries, stores up to 4,000 tons of aluminium coil, and uses trolleys with inductive power transfer.

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E-Mobility for Container Logistics

Battery-powered, emissions-free transporters that operate without a driver are being used for the first time at HHLA Container Terminal Altenwerder (CTA). To quickly and frequently exchange the batteries in the onboard battery boxes, which can weigh up to 12 tons, Vollert Anlagenbau developed a fully automated handling station in close collaboration with Gottwald Port Technology GmbH.

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Automatic long items and small parts storage for aluminum profile systems

heroal's new high-bay warehouse has the capacity for 10,000 long items and 7,000 euro pallets. A centrally controlled intralogistics system from Vollert ensures a smooth material flow between infeed and outfeed.

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Vollert Anlagenbau develops a 260-ton automatic crane for Vallourec & Mannesmann Tubes

A 260-ton automatic crane is the latest highlight in Vollert's intralogistics programme for heavy-duty applications. Capable of travelling up to 2.7 m/s and featuring a 44-m span width, the crane has a 35-ton payload and will be used to transport heavy objects on site at the customer's steel tube plant in Düsseldorf-Rath. The world's market leader manufacturers steel tubes for applications in oil and gas fields, power plants, and the chemical and petrochemical industry.

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Friction wheels transport large gearboxes for painting

The SEW-EURODRIVE drive automation system by Bruchsal relies on a simple, flexible material flow system by Vollert Anlagenbau for coating large gearbox units weighing up to 3.5 tons. It combines the advantages of Power&Free systems and requires significantly fewer system components. Nevertheless, comparably high cycle times are possible.

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Yellow giants painted overhead

Liebherr breaks new ground with a new large-scale paint shop for hydraulic excavators: The components, weighing up to twenty tons, are conveyed through the system on a guided track while freely suspended. A special drive solution ensures optimal protection against explosion in the painting and drying booths.

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Moving and Painting Large Items Efficiently

F. X. Meiller Fahrzeug- & Maschinenfabrik commissioned its new facilities for coating large items in early July. Two 70 m-long painting tunnels installed in parallel offer space for 14 stations and can each take up to 12 items weighing 8 tons apiece. Two chain conveyor systems from Vollert provide the required pulling force.

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Oven for construction machinery

At Wirtgen GmbH in Windhagen, world market leaders in the field of cold milling for road construction, components weighing up to 30 tons are freely suspended. The steel construction of the 230 °C furnaces is completely separated from the transport steel construction to protect against energy losses. This is made possible by special drive technology. Even with the heaviest loads, it allows for gap bridging of 70 cm. In addition, it is wear and explosion proof. The system was designed by Vollert Anlagenbau in Weinsberg.

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Custom manipulator with three synchronous hoisters lifts aluminium profiles up to 18 metres in length

Schletter GmbH, the largest supplier of solar mounting systems in Europe, has commissioned Vollert Anlagenbau to design a custom manipulator with three hoisters that can work together or separately to lift profiles weighing up to 9 tons with a maximum length of 18 metres. The manipulator will be used in a new buffer warehouse and is extremely compact to ensure optimal utilisation of vertical space.

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50 tons of explosion-protected parts painted while suspended

With a new painting plant, Liebherr is setting the standard in commercial vehicle construction. At the plant in Ehingen, parts from mobile and crawler cranes weighing up to 50 tons will be painted while suspended in mid-air. Vollert Anlagenbau from Weinsberg is developing the intralogistics for this. Wirtgen and SEW-EURODRIVE are just two of the companies also backing the new technology.

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SSAB stores up to 6000 tons of steel in a high-bay warehouse

The steel manufacturer SSAB in Oxelösund produces steel plates in one minute tact cycle. The information which plate comes next for what customer is only available three minutes prior to the production exit, thus the intralogistics system must react with appropriate speed. The solution supplied by the Vollert plant engineering company from Weinsberg, is achieved by conversion from a surface warehouse to a high-bay warehouse system with two MEGA AS/RS that enable short cycle times despite loads of tonnages.

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A dream car every minute

Two stacker cranes in a high-bay racking warehouse supplied by Vollert Anlagenbau of Weinsberg ensure a fresh supply of new cars every day at the new BMW Welt in Munich. The short-stay warehouse provides 284 storage positions on four levels and is located 12 metres deep down in the belly of the huge delivery hall. From here, the cars are moved fully automatically to the so-called Premiere Arena – the centrepiece of BMW Welt – for presentation and collection.

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Caution, People Hard At Work!

When others are running out of steam, the engineers at Vollert Anlagenbau are just getting into their stride, specialising in intralogistics systems for heavy goods – especially for the metalworking industry. For the aluminium extrusion works of apt Hiller for example, Vollert developed a fully automated intralogistics system which facilitates an end-to-end material flow from the extrusion works to the processing department and then on to the downstream anodising plant and newly constructed shipping warehouse. Major parts of the new system were installed and existing systems modernised and integrated while production was ongoing. As well as a higher handling capacity, the virtual warehouse of the transport control system allows optimum utilisation of the space offered by in-process stores, even with different sizes of transport basket.

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