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Case Studies > Advanced Cold Storage Logistics for Sensitive Drugs at Roche

Advanced Cold Storage Logistics for Sensitive Drugs at Roche

Technology Category
  • Analytics & Modeling - Predictive Analytics
  • Functional Applications - Remote Monitoring & Control Systems
  • Functional Applications - Warehouse Management Systems (WMS)
Applicable Industries
  • Healthcare & Hospitals
  • Pharmaceuticals
Applicable Functions
  • Quality Assurance
  • Warehouse & Inventory Management
Use Cases
  • Track & Trace of Assets
  • Warehouse Automation
Services
  • Software Design & Engineering Services
  • System Integration
  • Training
The Challenge
The new cold storage warehouse in Kaiseraugst closes a previous logistical gap: In sterile production, which consists of different operations (manufacturing, filling, packaging, shipping) that cannot be completed in immediate succession, the company had been forced to temporarily store products outside the Kaiseraugst campus. This process was inefficient and created extreme challenges for their material handling efforts in light of the need for a closed cold chain. The new cold storage now ensures that all operations can be completed at the same location across short distances, all within the control of Roche – from sterile production to packaging and shipping of injectable and infusible medications via truck and air freight. The warehouse was constructed over the course of two years and went into operation in 2013.
About The Customer
F. Hoffmann-La Roche AG, or Roche for short, is an international pharmaceutical company headquartered in Basel, Switzerland. With more than 90,000 employees, Roche had sales of approximately 48 billion Swiss francs in 2015. This makes Roche one of the world’s largest enterprises of its kind. Roche develops drugs, diagnostic agents and medical devices, focusing on innovations that offer a distinct advantage over products and solutions already on the market. For a number of years, the Swiss pharmaceutical company has been pursuing an ambitious development strategy aimed at further improving its research infrastructure, creating attractive jobs, and sustainably expanding specific locations. This includes the Kaiseraugst location in the Swiss canton of Aargau, a cornerstone of Roche’s international production and logistics network.
The Solution
F. Hoffmann-La Roche‘s new cold storage logistics in Kaiseraugst essentially consists of an automated high-bay cold storage warehouse with 8,100 pallet locations, which is kept at temperatures between 2 °C and 8 °C. In addition, a deep-freeze warehouse kept at –10 °C offers room for 196 pallets. Both warehouses are largely independent: The cold storage warehouse is for temperature-sensitive pharmaceuticals, the deep-freeze warehouse for refrigerated containers and cooling elements needed for shipping. The cold storage logistics is connected to an annex with four floors (lower level, ground level, first and second upper level). The lower level is connected via a tunnel system to storage areas in production and packaging. The ground level is linked to the receiving and shipping areas with their four loading docks. The first upper level houses bulk picking of entire storage units as well as “pick and pack” for production, packaging and shipping. The deep-freeze warehouse is located on the second upper level. For Hans Reimann, project Lead and Senior project Manager at Roche, the biggest challenges were completing all construction and installation work during ongoing operations as well as coordinating between external and internal distribution centers. Sophisticated planning and systematic implementation made it all possible. Equally difficult was developing constantly new processes which had to be implemented within very short project phases. Designing the cold storage workstations was challenging as well because they had to meet strict ergonomic guidelines.
Operational Impact
  • The high-bay cold storage is a self-supporting steel silo structure with a height of approximately 29 meters and a volume of more than 40,000 cubic meters. It operates at 2 °C to 8 °C. The roof and wall cladding is attached directly to the supports and roof girders without using additional components. The base plate is 10 meters below ground so that from the outside the structure has a visible height of 20 meters above ground. The cold storage has four aisles for single-deep storage. Storage and retrieval of the 8,100 pallets is fully automated using Vectura cranes from Swisslog. Their clear height is 26.5 meters, and the aisle length is 73.57 meters. Each crane has a maximum load capacity of 1,000 kilograms per storage or retrieval unit. The system can handle approximately 120 in- and outfeeds per hour.
  • The deep-freeze storage is a channel storage system consisting of a freestanding steel structure. It houses 2 x 10 channels with 5 pallets each and 2 x 8 channels with 6 pallets each. Of the 196 pallet locations, 54 are suitable for weights up to 1.4 tons while the others can handle weights of up to 1 ton. The deep-freeze storage has one aisle. A fully automated multi-depth crane with multiple load handling attachments can access all channels; their ends are equipped with push-through guards. The system can handle approximately 40 in- and outfeeds per hour. For safety reasons, the area is surrounded by a fence with a height of two meters which has four access doors.
  • The entire storage facility is cooled using recirculating cooling units. Fire safety is ensured through inertization (reducing the oxygen concentration of the air). Air locks and air curtains minimize the temperature and air exchange between the various storage areas. The new high-bay cold storage is separated by reinforced-concrete firewalls from an adjoining warehouse and a building used to transfer stock. A staircase tower attached to the outside facade of the warehouse acts as an escape route from the service platforms for the cooling units and allows roof access for repair and maintenance purposes.
Quantitative Benefit
  • The high-bay cold storage warehouse has 8,100 pallet locations.
  • The deep-freeze warehouse offers room for 196 pallets.
  • The high-bay cold storage operates at temperatures between 2 °C and 8 °C.

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