K2 Systems: A Logistics Project with Solar Flair

From planning the new hall to selecting suitable industrial trucks, redefining warehouse processes, and finding the perfect energy system, K2 Systems (a mounting systems specialist for photovoltaic systems) turned to the logistics expertise and 360-degree support of Linde Material Handling (Linde MH) and its local network partner to handle this complex project. A decision that would ultimately pay off in several respects.

K2 believes that even the most challenging projects can be made a reality if you leverage your strengths strategically. And the company doesn’t just work on any old projects, but focuses on probably the most important challenge of our time: converting our energy supply to renewable sources. Headquartered in Renningen, Baden-Württemberg, K2 is one of the world’s leading manufacturers of solutions for mounting photovoltaic systems on the ground, flat or pitched roofs, facades, or carports. Amid the worldwide solar boom, the medium-sized company also has a clear need for intelligent solutions for its internal material flow.

For a project of this size, you need someone who can do everything

“With demand constantly increasing, we needed to consolidate our warehousing by moving from several external warehouses to a central logistics center,” explains Logistics Manager Marcel Grilo. Since K2 Systems has already been taking advantage of Linde MH’s logistics expertise for many years, it made perfect sense to involve the network partner Hofmann Fördertechnik. “Everything needed to be seamlessly integrated: technology, processes and infrastructure,” says Grilo. And much to his delight, the ambitious plan was a complete success. Since the start of 2024, everything has been running like clockwork in the new logistics center, which has space for around 11,000 pallets.

Seamless Integration

In the new 7,500 square-meter hall at K2’s headquarters, things are moving at a rapid pace: the pallets are unloaded directly on the ramps using four Linde D12 HP SP. The warehouse management software generates individual labels when checking incoming goods, so that each goods carrier can be digitally traced; at the same time, the WMS assigns storage locations to the goods. Four Linde R14 HD reach trucks then transport the goods to the 4,700-storage location wide-aisle racking system for individual order picking or to the transfer point for storage in the narrow-aisle warehouse. There are three Linde K narrow-aisle order pickers working there (which also receive their coordinates via the WMS) that store and retrieve 60 pallets per hour around the clock. “At the moment, the storage locations are still approached manually. In future, however, we would like to switch to automated navigation in the eleven rack aisles,” explains Grilo.

Floor Compensation System Replaces Expensive Infrastructure Work

When designing the new logistics center, there was also the question of ensuring that there was suitable flooring for the high-rack order pickers. “We had in-depth consultations with Hofmann Fördertechnik on this,” says Grilo. “They helped us go through everything with a fine-tooth comb and in the end the decision was clear: investing in a floor compensation system for the narrow-aisle trucks is much cheaper than expensive VDMA-compliant flooring.” In light of this, K2 Systems ordered the Linde K trucks with the innovative Linde Active Stability Control (ASC), which allows operators to work safely and quickly on regular industrial floors.

Top Performance for Order Picking in High Shelving

In addition to ASC, the high-shelving order pickers are also equipped with Linde Dynamic Reach Control (to reduce mast vibrations at high lifting heights) and the Aisle safety assistant (ASA). “If you want your employees to work efficiently and show dedication, you need to make sure they are healthy and happy” says Grilo. For this reason, K2 staff were involved in the truck selection process from an early stage and some of the trucks were tested in advance at the Linde plant in Reutlingen. The team was particularly impressed by the excellent quality of the ergonomics of the Linde K trucks, which can be operated while sitting or standing.

Healthy Situation for High-Turnover Items

For K2 Systems, the motto “No compromises on Ergonomics & Safety“ didn’t just apply in the high-shelving area. Taking truck unloading as an example, a fully decoupled driver’s workplace on the Linde D12 HP SP reduces the physical strain on the operator. In addition, the Linde Safety Guard automatically reduces the speed of the trucks when the employees drive them into the trailers. This not only benefits our colleagues, but also the neighborhood: “Because we are located in a residential area, the reduced noise pollution when driving in and out is, of course, very welcome here,” says Grilo with a grin.

Sustainable Energy Concept Rounds off the Overall Package

Warehousing: consolidated. Processes: reorganized. Devices: optimally integrated into the processes. And the energy supply? Sustainable in every respect. In Renningen, PV modules on the roof of the hall and on the facades deliver a peak output of almost 750 kW. The renewable electricity is used to supply both the 14 company-owned e-charging stations for the (exclusively electric) car fleet and the energy storage units for the industrial truck fleet. K2 Systems uses lead-acid batteries for the Linde K trucks and the Linde R14, with a spare battery kept ready for each truck and charged during the day. The Linde D12 HP SP have Li-ION batteries, which are opportunity charged during work breaks. “This charging system allows us to really get the most out of our PV systems, especially as the spare batteries act as a kind of energy storage system,” says Grilo.