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How EPG Consulting Is Future-Proofing Hörmann’s Automated Small Parts Warehouse

18.08.2025

Cloud, Control, Capacity.

Hörmann KG, a leading provider of doors, gates, frames, operators, access control, and storage systems, has relied on the Ehrhardt Partner Group’s (EPG) Warehouse Management System (LFS) for many years—building on a partnership defined by trust, technical expertise, and a shared vision for forward-looking logistics. This close collaboration has proven its value at numerous sites worldwide. At Hörmann KG Antriebstechnik in Steinhagen, the planning phase has now begun for a groundbreaking modernization project. Independent consultancy EPG Consulting will not only develop a comprehensive modernization concept but also coordinate the implementation phase of a holistic retrofit of the Automated Small Parts Warehouse (ASPW). This includes the connected container conveyor technology, goods receiving and picking stations, as well as the container buffer in production. The project goes beyond mechanical upgrades, electrical and control system components, and production waste handling. It also encompasses system visualization and emulation through EPG’s fully cloud-based Warehouse Control System (WCS). The goal: to bring the facility up to state-of-the-art standards, streamline operations, and prepare it for the demands of the future.

The Automated Small Parts Warehouse (ASPW) at the Steinhagen site is a central pillar of intralogistics at Hörmann KG Antriebstechnik. Featuring eleven storage aisles—two of which are equipped with double-deep storage to increase capacity—the system provides space for up to 18,640 storage locations. The ASPW is designed to accommodate an exceptionally wide range of load carriers: standardized plastic containers with heights of 170 mm and 220 mm, as well as a variety of carton formats up to 900 × 400 × 280 mm in size, each with a maximum weight of 50 kg. This diversity enables efficient storage of items with very different dimensions within a single system but also places high demands on the control technology, which must reliably manage both varied transport and storage strategies. To ensure these requirements are met in the future, the planned retrofit includes a full modernization of the container conveyor system. New PLC systems will replace the existing controllers. The upgraded system components will not only guarantee a seamless connection between the ASPW and the eleven picking stations but also integrate key production areas efficiently into the material flow.

New Control Logic as a Performance Driver

A central objective of the planning phase is the evolution of the existing control logic into a modern, future-ready solution that is perfectly aligned with the requirements of an efficient material flow concept. To achieve this, EPG Consulting is developing a next-generation control logic that intelligently prioritizes transport tasks, proactively avoids bottlenecks, and significantly reduces cycle times—particularly in dual-cycle operations.

At the heart of the concept is the seamless integration of all eleven stacker cranes into the new system architecture, including the retrofitting of older units with modern camera systems. A special focus is placed on intelligent route optimization to further enhance the overall efficiency of the ASPW.

Cloud as an Enabler for Simulation and Virtual Commissioning

A key component of the project is the planned replacement of the existing WCS with EPG’s cloud-based WCS solution. This shift not only centralizes IT infrastructure and enables location-independent access but also opens the door to state-of-the-art tools for emulation and virtual commissioning. These capabilities make it possible to model, test, and optimize planned material flow strategies in a realistic environment—long before the first physical adjustments are made. »Especially in retrofit projects, the combination of cloud technology, virtual commissioning, and new control logic is a powerful lever to implement projects faster, more safely, and with minimal downtime,« emphasizes Marcel Wilhelms, General Manager of EPG Consulting. »Our goal is to make modernization seamless, transparent, and future-ready. The planning phase plays a key role in this: it lays the foundation for ensuring that the subsequent implementation runs smoothly both technically and organizationally.«

More Output, Less Downtime

The existing system, with its eleven efficiently designed pick-pack stations—equipped with carton erectors, paper cushioning inserters, and label applicators—will remain a central part of the picking processes even after project completion. Working in tandem with a powerful conveyor system, this setup achieves an average daily throughput of around 13,500 pick positions. Strategically placed buffer zones for empty containers, special cases, and returns ensure consistently stable material flows and enable precise control at every level. From the warehouse management system to the PLCs and camera systems, all relevant interfaces are integrated into the overall concept from the very beginning. EPG Consulting is responsible for the holistic system architecture, eliminating media breaks and ensuring a robust, future-ready process landscape throughout.

Trust as a Project Driver

»Our collaboration with EPG Consulting is characterized by mutual trust, technical expertise, and reliability,« says Torben Brandy, Project Manager at Hörmann KG Antriebstechnik. »Especially in a complex retrofit project, it is crucial to have a partner at your side who not only brings technical know-how but also understands our processes, is familiar with industry-specific requirements, and actively shapes the planning together with us. An important factor in this was the early involvement of our ASPW employees, ensuring their experience and improvement suggestions were directly taken into account. Our goal is to implement the modernization in a way that goes beyond mere optimization and truly contributes to the further development of our company—and that is exactly where we are working together.«

Proven Strength, New Intelligence

The project is currently in an intensive, detailed planning phase, during which technical, procedural, and organizational aspects are being precisely aligned. With implementation and commissioning scheduled to begin by Q3 2026, the retrofit will not only significantly extend the lifecycle and performance of the ASPW but also establish a solid foundation for future digitalization and automation initiatives. »With this planning, we are creating the conditions for a powerful and adaptable logistics setup,« Brandy summarizes. »The combination of cloud technology, a new control architecture, and carefully designed material flow planning will sustainably optimize our processes. In doing so, we are consistently relying on the experience and innovative strength of EPG Consulting—from the initial idea to successful completion.«