News
SAP EWM Manages 2D Shuttle System at Gerolsteiner
27.05.2026
Körber Implements High-Performance Warehouse with State-of-the-Art 2D Shuttle Technology
Gerolsteiner Brunnen GmbH & Co. KG is constructing a new compact pallet warehouse with a 2D shuttle system at its headquarters in Gerolstein for the storage and distribution of finished goods, as well as an automated truck loading facility. As the general contractor, Körber is responsible for the turnkey implementation of the entire system, including the shuttle warehouse, pallet conveyor technology, the integration of the automated truck loading facilities, and the control and optimization of the entire system using SAP EWM.
High storage density, redundant, and scalable
At the heart of the facility is a high-performance 2D shuttle warehouse with 15,800 pallet storage locations in channels that can hold up to 11 pallets and allow for storage and retrieval from both sides. In the first construction phase, the warehouse will be operated with 16 ATLAS pallet shuttles and four lifts from Körber’s partner Movu. These enable the storage and retrieval of up to 90 and 190 pallets per hour, respectively. As performance requirements increase, throughput can be increased to 180 storage and 290 retrieval operations per hour by integrating additional shuttle vehicles and lifts. The entire system is designed to be redundant and resilient; individual vehicles or lifts can take over the tasks of others as needed.
Business Logic in SAP
Körber implements all key components of the business logic for warehouse control—including optimization of the 2D shuttle—directly within SAP EWM. SAP EWM will manage the inventory of the 2D shuttle warehouse with precise location tracking and is responsible for putaway and retrieval strategies. Furthermore, SAP EWM handles the optimization of shuttle roaming and the lifts. This architecture provides maximum transparency, efficiency, and organizational flexibility for future optimizations: changes can be made on a single system by a single IT vendor—a major advantage from the client’s perspective.
Another task of SAP EWM is the sequencing of pallets for optimized outbound and transport logistics to retailers. »The seamless, centralized orchestration of all key processes via Extended Warehouse Management and the powerful, redundant shuttle warehouse ensure maximum operational reliability with high, continuously scalable performance,« says Ingo Windshügel, Senior Vice President at Körber Supply Chain Consulting. Despite the sometimes complex hardware and software requirements, the commissioning of the new warehouse—including the optimization phase—is still scheduled for the first half of 2027—less than 12 months after the racks are installed.
Investing in Future Viability
»As the market leader in branded mineral water, we are making targeted investments in our future viability. A high-performance logistics system that grows with our requirements is a key factor in this,« says Harald Jakoby, Head of Technical Planning at Gerolsteiner. The shuttle warehouse’s high space and energy efficiency is an important contribution to the company’s sustainability strategy; the intelligent networking of all processes via SAP EWM increases efficiency and reduces loading and unloading times at the loading dock.