3,500 tons of aluminum profiles per year require logistics that keep pace. TIR Technologies, a specialist in sun protection solutions, has consistently automated its storage processes, gaining space, transparency, and flexibility. With KASTO's intelligent storage technology, complemented by a sector-specific KASTOfenestra station, material flow, ergonomics, and productivity have since gone hand in hand.
The numbers speak for themselves: Every year, TIR Technologies moves and picks tons of aluminum profiles with lengths of up to 7.5 meters. The French company, based in Kilstett, north of Strasbourg, has been manufacturing sun protection solutions such as awnings, pergolas, blinds, and shutters for over 20 years. With 330 employees, TIR achieves an annual turnover of 110 million euros – a considerable size that places high logistical demands.
To specifically support production and utilize improvement potentials, TIR Technologies has relied on automatic storage systems and sector-specific solutions from KASTO since 2019. Two systems are currently in operation, internally referred to as 'KASTO 1' and 'KASTO 2'.
KASTO 1, a UNIGRIP honeycomb storage system with 1,200 storage locations, reliably supplies the pergola assembly with the required profiles. In 2022, KASTO 2 followed as another automated honeycomb storage of this type. With 2,000 storage locations at a height of 13 meters, the system manages the aluminum profiles for awning production. The special feature: KASTO 2 handles a technically demanding task – on minimal space, two different cassette types are managed simultaneously with just one storage and retrieval machine (RBG).
For TIR Technologies, the switch to automated honeycomb storage pays off significantly: On the same area, the systems now store double the amount of aluminum profiles, as they optimally utilize height and thus maximize the existing capacity. Every entry and exit is automatically recorded, elaborate lists and manual transports are eliminated, sources of error are minimized, and staff is noticeably relieved. The profiles are stored dry, protected, and always ready for the next production step.
The entire process is controlled by the Warehouse Management Software KASTOlogic – the brain of the warehouse: It coordinates incoming and outgoing storage, optimizes travel routes, monitors material flow in real-time, and ensures that production runs smoothly, safely, and efficiently. Thus, efficient material handling becomes a real competitive advantage for TIR Technologies.
Precision through sensors and control
The adaptation of KASTO 2 to the project-specific requirements required extensive development work in mechanics and software. The storage and retrieval machine of the UNIGRIP honeycomb storage is designed to accommodate profiles with six meters in length on one side and profiles with 7.5 meters in length on the opposite side in cassettes.
A dual sensor system on the storage and retrieval machine detects the respective cassette type and its exact position. This information is crucial for precise braking processes and the safe transfer of the load. Additionally, KASTO engineers adjusted reference points and gripper travel cycles to reliably represent different travel paths along the transport chain.
Patrick Barbier, IT manager at TIR Technologies, explains: 'Thanks to this customized solution, we were able to implement a storage system that would otherwise not have been feasible in the given space. At the same time, the automatic system allows us to achieve a significantly more efficient and better-planned production.'
When profiles know where they belong
Material flow is not a coincidence. For window profiles to arrive exactly where they are needed, a metronome that thinks ahead is required. KASTOfenestra align takes on this role: as a central circular station for the storage and retrieval of profile material, it keeps processes moving – safely, precisely, and without unnecessary stops.
Even when placing customer frames, the difference is evident. An integrated horizontal centering aid at two to three meters in height guides the frame into the correct position almost by itself. The forklift driver places it down without maneuvering, without corrections – quickly, accurately, and stress-free. The storage can be done either manually via a positioning stop or automatically with a manipulator. Subsequently, hydraulic lowers take over and lower the customer frame in a controlled manner until it sits exactly in the cassette.
To prevent material flow from stalling, KASTOfenestra align has two cassette spaces. While frames or packages are already being stored, the next space is already ready. Waiting times are thus a thing of the past. The station is individually tailored to the existing customer frames and integrates seamlessly into existing intralogistical processes.
Whether in window, door, or facade construction, awnings, pergolas, or shutters:
Wherever profiles of different lengths and geometries need to be efficiently picked, provided, and stored or retrieved, KASTOfenestra solutions ensure order and speed.
Automated storage solutions such as honeycomb or through-storage create the basis for structured, space-saving processes. Directly integrated into production, they provide the appropriate profile for each processing step at the right time.
From concept to commissioning
For TIR Technologies, technical competence and practical solutions were at the forefront of the collaboration. KASTO implemented the requirements with individually designed systems and a clearly structured project approach. Planning, implementation, and commissioning were coordinated and carried out in close communication between both companies.
An additional advantage was the geographical proximity: The KASTO plant in Achern is about 30 minutes from the production site in Kilstett. This allows technical questions to be clarified quickly and coordination to be carried out efficiently. 'Since the beginning, KASTO has been supporting us in purposefully further developing our profile handling,' says Patrick Barbier.
Optimization of material flow
The two KASTO systems form the foundation of a well-thought-out, holistic logistics concept at TIR Technologies. Material flows are purposefully controlled, bottlenecks are avoided, and processes are efficiently organized. A central advantage is evident in the delivery: The aluminum profiles are now stored protected in the automated warehouse, eliminating the need for elaborate packaging for raw materials. For suppliers, delivery is therefore simpler and more cost-effective – an effect that directly increases efficiency at TIR. At the same time, the reduction of packaging material makes an important contribution to sustainability: Less waste, less transport volume, and lower resource consumption benefit both the environment and the entire supply chain.
Especially crucial for production: The automated systems and the KASTOfenestra station enable the planning and handling of significantly larger quantities and production volumes than before with manual warehouses. Processes become more stable, workflows more predictable, and the acquisition costs amortize faster as capacities are optimally utilized.
The combination of a well-thought-out logistics concept, automated systems, and intelligent material handling creates an economical, predictable, and future-proof material flow that sustainably supports the production capacities of TIR Technologies and makes the entire supply chain more efficient.
Outlook: Partnership with Perspective
TIR Technologies continuously develops its internal processes and prepares for future growth. The successful collaboration with KASTO forms an important foundation for this: Previous projects have shown how modern storage and material flow solutions can contribute to greater efficiency, transparency, and process reliability.
“KASTO has proven to be a reliable partner for us,” says Patrick Barbier. “This wealth of experience is valuable for us in future considerations for the further development of our logistics.” Thus, the partnership between TIR Technologies and KASTO remains a central building block for a long-term, high-performance, and future-oriented logistics.
Author: Fabian Reiβ, Marketing, KASTO Maschinenbau GmbH & Co. KG, Achern
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