TDDK opts for iFD software once again for its plant expansion

TD Deutsche Klimakompressor GmbH in Bernsdorf, Saxony, which has been using the iFD forklift guidance system for automated production supply since 2017, opted for the iFD material flow control system – iFD WarehousePilot – in 2023 as part of the expansion and automation of its warehouse.

TD Deutsche Klimakompressor GmbH (TDDK) is a company owned by the Japanese automotive suppliers Toyota Industries Corporation and Denso Corporation, which manufactures compressors for car air conditioning systems. TDDK is a leading manufacturer in this sector in Europe.

In September 2022, the decision was made to switch to electrically powered compressors in the long term. Just nine months later, in June 2023, construction began on Hall 6 with a symbolic ground-breaking ceremony, and by April 2024 the topping-out ceremony for the sixth construction phase had already taken place. This adds 17,500 m² to the existing 73,000 m². Completion and commissioning are scheduled for June 2025.

The most important part of the extension is the 5-aisle, double-depth automated high-bay warehouse with more than 13,000 pallet spaces. With its 13 racking levels, it extends across three store floors. On each of the three floors, there are several storage and retrieval points for the high-bay warehouse. The three floors are connected by lifts. On the ground floor, there is an electric floor conveyor that connects the high-bay warehouse with the storage and retrieval stations on this level.

The project is being developed in close collaboration with Toyota Material Handling Germany, which is supplying the new racking system – including the connecting conveyor technology and the electric floor conveyor – for the project, as well as taking on overall project coordination as the main contractor.

The new automated warehouse works closely with the existing iFD forklift guidance system. The SLS sends transport, storage and retrieval orders for the pallets in the high-bay warehouse to the iFD WarehousePilot, which selects the pallet suitable for retrieval from the stock in the high-bay warehouse.

The handover or acceptance of pallets onto the conveyor system is carried out by forklifts or an automated guided vehicle (AGV) system, which receive the transport orders from the iFD forklift control system.

The WarehousePilot software is responsible for the entire transport management of the automated system. It organises the inbound, outbound and stock transfer operations in the high-bay warehouse, initiates and coordinates the smooth interaction of transport operations for the pallet conveyor system, the lifts, the EBB and the RBGs. In doing so, the software monitors the flow of pallets and takes into account the utilisation of the individual conveyor system components when controlling transport.

The WarehousePilot software includes a WMS module that handles bin searching and storage location management for the new high-bay warehouse.

We are delighted to have been awarded this contract and appreciate the trust placed in us, and we look forward to working together to realise the project.