Efficiency and state-of-the-art logistics for premium beers: there’s something special brewing in Weiden

The HEINEKEN logistics centre in Weiden, Germany is a hive of activity. Thousands of pallets of premium beers are handled here every day on an area measuring 32,000 square metres. Boasting an impressive capacity of up to 150,000 pallets every year, the site keeps the market in southern and eastern German well supplied. By opening this ultra-modern central warehouse, HEINEKEN Germany has taken a decisive step towards optimising its supply chain. Sirl Interaktive Logistik GmbH, based in Unterschleißheim, operates the warehouse and is responsible for handling the goods on behalf of the Dutch brewery group. The site is thus becoming a central logistics hub for top beer brands such as Heineken, Desperados, Gösser and Birra Moretti. While the warehouse might appear to be a typical storage location at first glance, a closer inspection reveals this to be a logistical masterpiece with an array of moving parts.

A site with history – and a future

The warehouse on Dr.-Kilian-Strasse has an eventful history behind it. It originally served as a dispatch centre for a car parts dealer before it was shut down in 2021. Following extensive renovation work, the site is hardly recognisable today. “We had a tight schedule,” recalls Konrad Götz, Head of Warehouse Logistics and Production at Sirl. “The order from HEINEKEN came in summer 2023, and we had to be fully operational by 1 January 2024.” In fact, the former dispatch centre underwent a complete upgrade to adapt it to the specific requirements of drinks logistics.

From the brewery to the shelf: processes in the HEINEKEN central warehouse

In terms of day-to-day operations, the warehouse moves up to 3,500 pallets on peak days. This corresponds to around 100 fully loaded lorries with up to 140 loading and unloading cycles per day. Deliveries are mainly made by lorry from various breweries in the HEINEKEN Group. The delivered pallets are always unloaded from the rear, an approach that allows for rapid, straight-on delivery to the ramp and which can be carried out efficiently with lighter equipment.

Once the goods are unloaded, the crucial receipts process begins. Each pallet is digitally recorded, visually inspected and entered into the warehouse management system (which in turn is connected to the central HEINEKEN system), ensuring complete transparency for all items in the warehouse. Goods are stored in two different warehouse areas. Most go into block storage, which is ideal for high-speed trucks and rapid turnaround times. Items with special storage requirements or a slower turnover can be stored in the high-bay warehouse, which has around 4,000 storage locations.

Handling in the warehouse varies significantly from season to season. “When the sun comes out in spring, we have to double our volumes within a few days,” says Götz. Public holiday periods such as Easter or Christmas in particular call for maximum flexibility in personnel and transport planning. A well-oiled team of permanent employees gets backup from temporary staff and seasonal workers.

Picking is carried out both on a full-pallet basis and at item level. Customer orders are processed in the warehouse management system and the respective items are taken from the block or high-bay warehouse and prepared for dispatch. Customised packaging is particularly important for promotional products such as displays for Desperados. Deliveries are prepared for loading in the outgoing goods area before being loaded onto the waiting lorries.

Special attention is paid to empty bottles and containers, as reusable packaging makes up 70 percent of the items handled in the warehouse. These empties are collected, sorted and prepared for return in an outdoor area covering 12,000 square metres. “Empties have to be stored separately from full containers for hygiene reasons,” explains Götz. Sorting is also carried out according to container type, brewery and packaging to ensure that they can be seamlessly returned to the logistics cycle.

Intelligent technology in use: STILL industrial trucks increase performance and safety

Sirl relies on industrial trucks from STILL to handle complex logistical tasks in the warehouse. “We deliberately opted for electric forklift trucks with lithium-ion technology. They are low-maintenance, energy-efficient and flexible thanks to interim charging,” says Götz. In combination with a planned PV system that will enable the building to produce its own electricity, the result is a sustainable setup that operates entirely without fossil fuels. A total of five new 3.5-tonne RX 60-35 electric forklift trucks in a special version for the drinks industry, seven EXH-SF stand-on low lift trucks, two 6-tonne RX 60-60 electric forklift trucks and two MX-X very narrow aisle trucks for serving the shelves were purchased. All trucks are equipped with high-performance lithium-ion batteries with a voltage of 80 V and a nominal capacity of 1,258 Ah with a charging time of around 3.2 hours.

STILL worked closely with its customer Sirl to customise the trucks. In addition to the classic version of the RX series for the drinks industry, the forklifts were equipped with custom options such as STILL Safety Light 4Plus safety lighting, multi-pallet clamps and the FTC Protection System from HEINEKEN to ensure safety for personnel and in danger zones. A wireless zone detection system is also used to automatically regulate the speed of trucks, especially in heavily frequented zones.

Even before the start of the project, Sirl had been using other STILL equipment at the site, including RX 60-30 electric forklift trucks configured for the drinks industry, FM-X 14 reach trucks as well as racking systems and low lift pallet trucks with Li-ion technology. Over many years of purchasing products from STILL, the two companies’ relationship has grown into a full-fledged, trusting partnership.

High-performance, high-speed trucks for incoming goods

Seven STILL EXH-SF low-lift pallet trucks with different fork lengths are used in the incoming goods area, which can also pick up pallets deep in the lorry. These industrial trucks are designed to unload lorries in the shortest possible time and distribute the pallets quickly to the various areas of the warehouse. Thanks to their high driving speed and the folding stand-on platform, the high-speed trucks can move flexibly between the storage zones and safely transport even heavy loads.

RX 60-35: The heart of order picking

Six STILL RX 60-35 electric forklift trucks configured especially for the drinks industry are used for goods storage and order picking. Equipped with multi-pallet clamps, these forklifts can pick up several pallets at the same time to streamline transport routes while significantly increasing picking efficiency. The lithium-ion technology also boosts truck availability, as they are ready for use whenever needed thanks to short charging times.

Robust electric forklift trucks for outdoor use

Two STILL RX 60-60 electric forklift trucks with multi-pallet clamps and a 6-tonne load capacity are used in the outdoor area of the warehouse, where managing empties is one of the main tasks. These forklifts are specially designed to work reliably even under demanding conditions. They can pick up six pallets in one go, making them an efficient solution for moving large quantities of empties. Their robust design and high load capacity make them the go-to truck for outdoor use.

Up and away with the MX-X very narrow aisle truck

Two STILL MX-X very narrow aisle trucks are used to store special products in the high-bay area. These trucks are designed for working in narrow aisles and, thanks to their maximum lifting height of up to 18 metres (Sirl stores products up to a maximum height of 10 metres), they enable optimum use of storage capacity. Offering precise control and the ability to move pallets at height, they are indispensable when it comes to high-density stock storage in the warehouse.

Strict safety concept

When it comes to safety, HEINEKEN sets the bar particularly high and applies stringent standards in terms of protection devices for its employees. But STILL assistance systems are also rated highly in this area, as Konrad Götz confirms: “We use wireless collision avoidance with truck-to-truck and truck-to-person communication. There is also a 360-degree camera system on each forklift to help our drivers navigate. In high-risk areas, the maximum speed of the truck is automatically reduced by the truck software for ultimate safety while still processing high volumes.”

Clemens Festner, Regional Sales Manager at STILL GmbH, sees the HEINEKEN drinks warehouse with its sophisticated safety concept and function-focused industrial trucks as an ideal example of what good cooperation between project partners should look like: “Sirl got us involved at a very early stage and we were able to tailor the truck design precisely to the requirements. Flexibility is crucial, especially when retrofitting individual safety and comfort features. But it was also key that we were able to deliver at very short notice. When the time frame is that tight, every week counts – and we were able to guarantee that all the equipment would be available on time for the go-live date.” Festner notes that this successful project clearly underlines how crucial mutual trust and finely tuned processes are in terms of an efficient overall solution. “The technology, timing and teamwork all have to fit – it’s the only way to get a solution this effective.”

Forward-looking logistics

Today, the new HEINEKEN central warehouse is much more than just another distribution centre; it sets a precedent for modern, scalable and sustainable logistics in the drinks sector. Despite – or perhaps because of – the success story in Weiden, Sirl is already thinking ahead: “We are already planning our next warehouse project – and it goes without saying that we’ll be working with STILL again,” confirms Götz. The combination of innovative technology, proven warehouse experience and close collaboration forms the foundation of future-ready drinks logistics solutions. All of which makes it clear that the perfect brew hasn’t just been created in Weiden: efficient logistics has a truly special flavour of its own.