Ahlsell Expands Logistics Center with KNAPP Solution

Ahlsell, Sweden’s leading provider of installation products, tools and accessories, has opted to expand their logistics center in Hallsberg using KNAPP technology. The expansion resulted in an additional 30,000 square meters (320,000 ft²) of warehousing space and represents Ahlsell’s largest investment in automation to date. It has doubled the logistics center’s capacity and laid the foundation for the company’s future growth. The project also marks the next step in the long-term partnership between Ahlsell and KNAPP. The system is scheduled to come on stream in late 2027/early 2028.

KNAPP warehouse logistics doubles capacity

Ahlsell’s logistics center in Hallsberg, which is one of the largest warehouse facilities in Scandinavia, has already undergone several expansions. The large product range – with over 100,000 products in stock – and Ahlsell’s promise of next-day delivery place extremely high requirements on the system’s intralogistical capacity and productivity. Laying the foundation for future growth was the goal of installing the comprehensive automation solution and expanding the warehouse by over 30,000 m² (320,000 ft²). To accomplish this goal, Ahlsell once again turned to KNAPP, who provided the very first automation solution for the logistics center 13 years ago.

“We made the largest investment in automation in Ahlsell’s history to meet our growing needs for capacity. Together with KNAPP, we’ve integrated innovative technologies to increase our warehouse capacity and improve both our delivery quality and our efficiency. This investment will more than double our warehouse capacity. It’s an important milestone in our mission to always be one step ahead in our industry and to provide our customers the best service possible in the most sustainable way,” says Daniel Johansson, Logistics Director of Ahlsell Sweden.

All-in-one automation solution for optimized logistics processes

The new automation solution was developed in close collaboration between Ahlsell and KNAPP and combines innovative technologies for maximum capacity, productivity and ergonomics. It also includes 27 highly automated decanting stations, high-bay pallet racking, the Evo Shuttle automatic storage system and 20 ergonomic work stations of the Pick-it-Easy series for goods-to-person picking. Different areas of the system will be connected by a fleet of 33 Open Shuttle Fork autonomous mobile robots (AMRs), which will transport pallets, and over 8 kilometers (5 miles) of conveyors. Once the new solution is in full operation, Ahlsell will be able to reduce lead times from order receipt to outbound delivery to 45 minutes or less.

“This is our largest project yet in Sweden and I’m very proud of the solution we’ve developed together. We selected an integrated approach to connect the old solution with the new one to create one single highly efficient process. Looking ahead to 2050, we’ve prepared ourselves thoroughly for the future by setting up additional picking stations and increasing our use of robotics,” says Mikael Holmqvist, CEO of KNAPP Nordics.

Ergonomics and noise levels in focus

A central aspect of designing the automation solution was improving the work environment for Ahlsell’s employees, with a particular focus on lowering the ambient noise levels. This focus resulted in ergonomic picking and decanting stations equipped with noise protection.

“Our promise to our employees is to provide them with the best time in their entire careers. For us, our employees are our greatest asset. A sustainable, healthy working life is important, and ergonomics and a good work environment are key to making it possible,” says Daniel Johansson.

Construction is slated to begin in the first quarter of 2025 and the system is planned to go live in late 2027 or early 2028.

Technology in focus

• 8 pallet cranes, around 58,000 pallet locations
• 6 aisles with Evo Shuttle racks, around 275,000 storage locations
• 27 ergonomic decanting stations
• 20 ergonomic Pick-it-Easy picking stations
• 12 carton erectors/cutters/closers
• 7 aisles with Evo Shuttle Vario racks, around 10,000 storage locations
• 33 Open Shuttle Fork AMRs for pallet transport
• 8 km (5 mi) of conveyors for pallets and lightweight goods
• KiSoft software by KNAPP for central warehouse and process control

About Ahlsell

Ahlsell is Sweden’s leading distributor of materials, supplies and tools for installation and is strongly positioned in all product areas in Sweden. They offer professionals a wide range of goods and associated services for HVAC, electrics, industrial applications, tools and machines, insulation, construction, real estate, plumbing, sanitation, consumable goods and personal protective equipment.

www.ahlsellgroup.com