Effi cient, forward-looking, customised. Simply clever, like Kardex Mlog.

EFFICIENCY

100%

Provenintralogisticsfor the pharmaceutical industry.

Doctors and patients trust you because

of your name. It‘s the same with us.

With more than 40 years of experience

and more than 900 successfully

implemented projects, we can justifi ably

claim to be among the top names in the

industry.

And maintaining this high level of

customer satisfaction is the challenge

that we extend to all our employees

and to our technology. Reliability, the

highest quality, 100% ability to deliver,

energy effi ciency, speed and innovati-

ve industry concepts are at the top of

our scale of values.

And these are no empty claims. We

invite you to peruse our reference

projects from page 11 onwards. After

you have done so, we would be

delighted to talk with you in person

and tell you all about us and what we do.

Satisfi ed customers,great projects

0 1 1Just some of oursuccess stories.

The very best references.

22Our industryexpertise for your highly effectivewarehouse.

03

We develop our plants based on designs

which are proven over and over but we

still manage to customise your facility

to your special requirements.

The pharmaceutical sector has special

requirements. We are aware of these and

we take account of them in our designs:

We guarantee compliance with

internationally required pharmaceutical

regulations and the directives of the

GXP, and especially with the

indispensable GAMP 5 for automated

plants.

Established operational procedures,

seamless process and batch tracing,

absolute cleanliness, temperature

tracking, energy management and

other requirements are standard in

our plants. With optimised

transport of materials, we reduce

access times and ensure

maximum energy effi ciency.

We manage all of this without

compromises, in refrigerated

storage areas, in clean rooms,

and with tagged products.

Exactly as you need it.

We knowwhat‘s important.

“Made in Germany” for a fair price,and available when you need it.

33Warehouse types differ.

Their objective, however,

is always the same:

maximum availability.

Our expertise covers planning and

project planning, through execution

and implementation, right up to

the overall service support during

productive operation.

We have access to our own

manufacturing and software

development (storage and retrieval

machines, pallet transportation

technology, material fl ow control)

where we develop the key components

of your facility in-house and customise

them to your requirements.

All from asingle source

Qualityactive ingredientsmake the best medicines.

05

Complete solutionsmanufactured by us in Germany.

No risks,no side-effects.

40 1

The modern warehouse, based

on state-of-the-art technology,

ensures energy-effi ciency and speed.

On the other hand, improperly-sized or

outmoded plants tend to have higher

fault rates, are more expensive to

operate and maintain, and can slow

the growth of your company.

Kardex Mlog develops customised

refurbishment concepts which can be

implemented rapidly during ongoing

operations.

From day one, you reap the benefi ts of

a modern, state-of-the-art plant – no

matter when it was built.

Refurbishmentduring ongoingoperations

0 7

Planning security, transparencyand precise logistics, tailored to meet your needs.

5Serviceis what we do best.

In addition to performance and

availability, maintenance and staff are

the critical factors that determine the

profitability of your logistics plant.

In these sensitive areas, Kardex Mlog

works together with customers to

develop tailor-made service solutions

adapted to the customers‘ specific

requirements. The solutions ensure the

long-term viability of the plant and

guarantee high delivery capacity.

From spare parts management through

modern diagnosis and visualisation

tools, right up to permanent, 24-hour

on-site service: MService provides

a flexible portfolio of professional

services.

Together, based on our modular

components, we can develop a

customised package solution for

your plant. Should your

requirements change, we will

adapt the scope of services

quickly and unbureaucratically.

This ensures maximum

availability and profitability for

your plant at all times - today

and into the future.

All-round service

09

Reliable, profi cient, fast.

66Thepharmaceuticalsindustry knows us.We know thepharma industry.

On these pages, you can read

about some of the projects we

have carried out - each with a

different challenge. We are proud

of the fact that, since the very fi rst

commissioning, all of these plants

have run trouble-free, day after day.

Well-knowncompaniesrely on us.

1 1

More than 30 projects for 15 major pharmaceutical companies over the last 20 years:

• Industry-specifi c solutions • Numerous follow-up projects and extensions

Neuenstadt/Debrecen – The market for low-cost pharmaceu-ticals and medicines is booming. The demand for generic medi-cines, which provide the same effects as the original drugs for a lower price, has been rising for many years.

To satisfy this demand, TEVA Pharmaceuticals, the Israeli global market leader in the generics sector, invested in Hungary.

Kardex Mlog, as the general contractor, constructed a new, three-aisle, high-bay warehouse and installed the entire materials handling technology for the company‘s additional production facilities in the country. Production output at the Debrecen location is being doubled to an annual volume of approximately 14 to 15 billion tablets and capsules in the form of almost 800 different products. This placed correspondingly greater demands on the warehousing capacity especially since the existing warehouse was al-ready operating at its limit:Over the past ten years – and including these recent measures – the output of medicines in Debrecen has increased tenfold.

Figure: TEVA Pharmaceuticals, global market leader in the generic drugs sector, expanded capacity in its Hungarian plant in Debrecen. Right: The pallet conveyor system connects the high-bay warehouse with the various work areas.

Figure: EURO pallets are stored and retrieved in the three aisles using storage and retrieval machines of type MSingle A.

Potential for further growthAs the general contractors, the specialists from Neuenstadt am Kocher were responsible for all aspects of the plant – from the steelwork to the conveying sys-tems and material fl ow control. The conveying system covers se-veral fl oors to enable pallets to be transported between the high-bay warehouse, goods inwards and outwards, and the various pro-duction areas. In total, the pallet handling system makes use of 130 drives and four shuttle cars. To handle cardboard boxes, Kardex Mlog installed a small parts con-veyor system with 50 drives. Pal-letising is fully automatic using a robot palletisation system with a

Confi rming the reliability and quality of the supplied plant, just 18 months later TEVA have once more commissioned Kar-dex Mlog to build a fully auto-matic buffer warehouse. This second plant, constructed within a few months, is in the same production location as the fi rst

Proven components inthe pharmaceutical industryThe newly-built, high-bay ware-house has three 85-metre aisles. It has a capacity of 4.860 storage locations for EURO pallets weig-hing up to 750 kg each. Each aisle is serviced by a storage and retrie-val machine (SRM) of type MSing-le A with single load-handling. With a height of 17 metres, each SRM has a capacity of 100 doub-le cycles per hour. The machines are proven in numerous phar-

maceutical industry applications and are – as is the case with the components of the Kardex Mlog conveying systems – suitable for use in particularly sensitive areas. The SRMs can be designed spe-cifi cally to suit any type of appli-cation. In Hungary, they are used with integrated camera systems – which has become the norm – and with single load-handling capability. In other sectors, such

as the furniture industry, MSing-le machines are operated with up to three-deep storage. „The fl exi-bility of our products allows us to create individual solutions based on proven technology“, says Ta-mas Zahornitzky. „This concept is a winner in challenging environ-ments such as the pharmaceuti-cal industry.“

capacity of up to 420 boxes per hour. The ability to subsequently connect additional plants to incre-ase capacity still further has al-ready been built into this custom-made solution and is therefore possible without incurring signifi -cant costs.

All processes are monitored and controlled by the central mate-rial fl ow control (MFC) system. Using the visualisation software, the processes and operating sta-tuses of the SRMs and convey-ing systems can be graphically displayed and monitored. A TCP/IP interface enables permanent data exchange with the various

components. The MFC system was integrated into the existing goods management system. The new building was commissioned less than a year after construc-tion began and Debrecen is once again among the most modern and most productive of the 37-odd global locations operated by TEVA Pharmaceutical Industries Ltd. Kardex Mlog itself is excel-lently positioned internationally and successfully promotes its concept of regional proximity. In Hungary, for example, Kardex Mlog operates a branch in Buda-pest.

Reference customer |

TEVA

plant but serves a completely different section of the supply chain; it is used for preparatory picking of the raw materials for production. It functions as a fully automatic daily buffer between the raw materials warehouse, the refrigerated warehouse, the clean-room warehouse, and the

eight clean-room cabins for raw material picking and has an au-tomatic interface with all the areas listed. Another project in which Kardex Mlog was able to demonstrate its many years of experience in the pharmaceuti-cals sector.

Fresenius Kabi, the leading pro-vider of infusion therapies and clinical nutrition in Europe, has expanded its Friedberg, Hesse, location to become its interna-tional logistics hub for the en-tire product portfolio. With this expansion, Fresenius Kabi has further increased the effi ciency of its logistics processes and, in the face of increasing demand, has ensured a seamless transiti-on to a smooth logistics operati-on and optimised fl ows of goods for the international delivery of its products.

Reference customer |

FRESENIUSAll the necessary building conversions and new construction work was car-ried out by the Kardex Mlog company from Neuenstadt. Kardex Mlog, a specialist in both disciplines, was commissioned to implement the concept which consisted of four steps: The existing ten-aisle high-bay warehouse 1 was extended to include an additional storage and retrieval line on the west side. The north and west high-bay warehouses were built from scratch with three and six aisles respectively. Finally, all the plant sections were con-nected using conveying systems and integrated into the overall material fl ow control. In total, the warehouse capacity was more than doubled from 35.000 to 75.000 pallet storage locations.

Figure: The existing plant (back) and the new building (front) were connected using the newly installed conveying system and integrated into the overall material fl ow control.

Figure: Large sections of the logistics centre were built from scratch, including the high-bay warehouse West (left) and the new logistics building including offi ces in front.At the back, to the right, is the existing warehouse.

Proven cooperationThe existing plant was extended with no interruption to ongoing operations. The on-site spe-cialists were very familiar with the local conditions since, when warehouse 1 was commissioned back in 1996, Kardex Mlog was

Technology close-upIn this current project too, Kardex Mlog relies on equipment and components from its own manu-facturing facility in Neuenstadt.

In the new building, the company installed six storage and retrieval machines (SRM) of type MSing-le B with a height of almost 30 metres. Of these, three identi-cal machines are in use in the north warehouse. All machines

are equipped with load-handling devices for two-deep handling. The storage and retrieval cyc-le fi gures here are 28 (high-bay warehouse North) and 33 (high-bay warehouse West). The SRMs are fi tted with S7-standard, fre-quency-controlled drives and con-trols and SEW MoviPLC motion control. Data transmission takes place via WLAN. As a result of the control technology used, a simple

energy management system to capture and document the actual energy consumption, and intelli-gent DC link coupling, a high level of effi ciency was achieved.

The energy requirement remains low even at high performance and running speeds of up to 180 m/min.

then the general contractor. In the interim period also, in the project to extend the convey-ing systems to the pre-storage area, Kardex Mlog was the pre-ferred partner. „The technology and components have stood the

test of time“, according to Bernd Heller, Project Manager for the extension of the logistics centre and Logistics Technology Mana-ger at Fresenius Kabi, „for this reason, we decided once again to go with Kardex Mlog.“

From Dortmund, help on a lar-ge scale is on its way for those patients with chronic respirato-ry illnesses. Here, in the eas-tern section of Germany‘s Ruhr district, Boehringer Ingelheim microParts GmbH manufactu-res inhalers under clean-room conditions.

Recently, the company expan-ded its production capacity to 20 million units per year.

Reference customer |

BOEHRINGERINGELHEIMIn the course of this expansion, a new high-bay warehouse and a separate clean-room warehouse were constructed. The general contractor for both projects was Kardex Mlog from Neuenstadt. Production of the sophisti-cated atomisers is a technically demanding process and the focus is on optimising the spray cloud which provides respiratory relief. In order for the human lung to be able to absorb the aerosol, the active ingredients must be broken down into fi ne, breathable particles and the spray cloud must re-main intact for long enough. Boehringer Ingelheim microParts GmbH spe-cialises in the exact reproduction of microscopically small structures on an industrial scale. Using microsystems technology, the company manufac-tures the patented Respimat® Soft Inhaler, whose micro nozzles generate the fi nest spray clouds for a period of approx. 1.5 seconds – up to ten times longer than conventional aerosols. Not only are there practical benefi ts for use; the device is also a very effi cient inhaler. Other products created in the Dortmund high-tech facility include micro-structured channel plates for medical diagnostics and analytics, and also micro-spectrometers.

Strict requirements forproduction and logisticsThe new atomiser factory in the Dortmund Technology Park occu-pies approx. 12.000 square met-res, of which a third is allocated to the clean-room area. The strict specifi cations were due not only to the medical technology stan-dards and directives, but were also a prerequisite for error- and

Separateclean-room warehouseIn cooperation with the Assmann planning fi rm, Kardex Mlog de-veloped a concept based on two separate entities. Whereas in the high-bay warehouse, most of the materials used were standard products, new ideas were needed with regard to the materials for the clean-room area. These inclu-ded the use of silicon-free mate-rials and stainless steel in place of conventional steel. The strin-gent requirements also affected

Conveying technologybetween the work areasSignifi cantly larger than the clean-room warehouse was the second warehouse area which Kardex Mlog constructed on the produc-tion site. Approximately 1.800 pallets are stored along two ais-les; these are serviced using two 29-metre SRMs of conventional design. The MSingles, of type B, developed in-house by Kardex Mlog, use their telescopic forks to handle different-sized pallets up to 1.000 kg. The standard fi t, frequen-cy-controlled, three-phase drives enable speeds of up to 100 m/min (travel) or 30 m/min (lift). Howe-ver: „The main focus was placed on the availability and risk-free connection of the clean-room are-as“, explains Stefan Rueß of Kar-dex Mlog regarding the company‘s

wastage-free production of the delicate parts. In line with these standards, the specifi cations for planning and construction of the new warehouse were also very precise. Implementation was ent-rusted to Kardex Mlog. Kardex Mlog is one of the world‘s leading logistics systems providers and,

the installation: For example, the racks and the storage and retrieval machines could only be installed during good weather in order to prevent damage to the clean-room walls of the warehouse. The clean-room warehouse today houses 56 pallet storage locations and is designed as a lifting-beam warehouse. Storage and retrie-val of the units takes place using a vertically mobile lifting beam on which a distribution shuttle

approach. „This applied in particu-lar to the conveying system. „This was also installed by Kardex Mlog and it connects all areas of the fa-cility from goods inwards to out-put of the inhalers. Between the clean-room areas and the general production areas, intermediate air-locked chambers and transition booths ensure maximum cleanli-ness. The entire plant is controlled through a connection to the central SAP system which controls all sto-rage and retrieval operations. The lower-level controls of the convey-or system and the storage-and-retrieval machines comply with the S7 standard and are integrated into the plant visualisation system via TCP/IP interfaces. Given the strict requirements of the project,

in Europe, is among the top spe-cialists for solutions in the medi-cal and semi-conductor industries which both have comparably strict specifi cations. The Neuenstadt-based company operates several Service Centres throughout Ger-many and Europe and one of the-se is in the Rhein-Ruhr region.

moves horizontally. The load unit is grabbed by the telescopic fork mounted on the distribution shut-tle. This new standard warehouse called MTower is the newest ele-ment in the Kardex Mlog program-me and provides a solution for smaller capacities up to approx. 500 pallet storage locations. It is especially appropriate for buildings with shorter but higher aisles and features excellent fl exibility. For example, you can choose between single and two-deep load handling and you can defi ne the load capaci-ty to suit requirements. Compared to the classic warehouse design with a single storage and retrieval machine, the capacity is 20 % hig-her. In the clean-room warehouse, Kardex Mlog installed a variant of this with a load capacity of 500 kg.

the implementation period was relatively short. The contract was awarded in March 2007 and the entire plant was commissioned in November 2008. Due to continued growth, further expansion of the high-bay warehouse is already pl-anned and this will double the cur-rent number of storage locations. Good news, not only for the users of the Respimat® Soft Inhaler, but also for the entire Rhein-Ruhr re-gion which is currently undergoing structural change. High-tech com-panies such as Boehringer Ingel-heim microParts GmbH are deli-vering highly qualifi ed jobs to the region. Since its establishment in Dortmund in 1994, the Boehringer workforce has grown from 40 to approximately 450 today.

Figure: The clean-room warehouse has been designed as a lifting-beam warehouse and accommodates 56 pallet storage locations. Storage and retrieval of the units takes place using a vertically mobile lifting beam on which a distribution shuttle moves horizontally.

Figure:

Figure: An important factor in the planning and implemen- tation of the plant was the secure connection and availability of the clean-room areas, especially with regard to the conveying systems. This connects all areas of the facility from goods inwards to goods outwards.

The novel MTower lifting-beam warehouse rounds off the Kardex Mlog range of standard warehouses. On averti-cally mobile lifting beam, a distribution shuttle moves horizontally. The load unit is grabbed by the telescopic fork for single or two-deep storage. This principle enables a capacity of 50 double-cycles per hour. Compared to the classic warehouse design with a single storage and retrieval machine, the capacity is 20% higher.

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AustriaBenelux

Czech RepublicFrance

HungaryItaly

SerbiaSwitzerland

Just some of our reference projects in the pharmaceutical sector Kardex Mlog Deutschland locations:

Neuenstadt (headquarters) Bremen Bad Salzufl en Oberhausen Munich Service partner locations

MLOG Logistics GmbHWilhelm-Maybach-Straße 274196 Neuenstadt am KocherGermany

Phone +49 7139 4893-2 1 3Fax +49 7139 4893-394vertrieb.mlog@kardex.com

www.kardex-mlog.com