Relocation of an Automated Storage System with Kardex Remstar, Optimizing Production with Zero Downtime

When it comes to smart warehouse automation, efficient equipment relocation and production optimization are critical. The relocation project of Dorma Germany’s automated storage system—a company with over 100 years of expertise in door opening and closing solutions—is a prime example of how Kardex Remstar enables fast, efficient implementation without disrupting production.

Real-World Challenges

Dorma decided to move its electronic production line from Bonn to its headquarters in Ennepetal to shorten the distance to the mechanical production line, improve manufacturing efficiency, and enhance customer service.

Key challenges included:

• Relocating 7 Kardex Megamat (VCM) automated storage systems, each 5 meters high and 4 meters wide, along with 8,500 components
• The former site in Bonn had limited space, was located on the second floor, and the floor could not support forklift loads
• The relocation had to ensure minimal downtime to avoid impacting production schedules

The Kardex Remstar Solution – Life Cycle Service

Drawing on experience from hundreds of storage system installations across Europe, Kardex’s Life Cycle Service team designed a detailed, safe process for dismantling, transportation, and reinstallation:

Professional dismantling:

• The Kardex Megamat systems were dismantled in reverse order of installation—from access doors, control panels, electrical cabinets, and storage carriers to the outer casing. Each 800 kg frame was placed on specialized creeper dollies and moved through double doors using pulley systems.

Flexible transportation:

• In Bonn: lifting platforms, lightweight trolleys, and low-load equipment were used
• In Ennepetal: cranes and forklifts enabled fast and safe reinstallation

Integrated maintenance service:

• Kardex conducted electrical inspections, replaced components where needed, and ensured that all systems operated smoothly immediately after reinstallation.

Achieved Results

• 7 Kardex Megamat systems successfully relocated over a distance of more than 100 km
• No production downtime—all components were ready for operation immediately after installation
• Optimized time, cost, and safety
• Storage systems fully adapted to the new location and ready for future expansion

See details here: CaseStudy_EN_Dorma.pdf

Core Value of Kardex Life Cycle Service

Kardex Life Cycle Service goes beyond simple dismantling and installation by offering:

• Strategic storage consulting
• Professional relocation planning
• Extended system lifespan through regular maintenance and upgrades

Conclusion

The automated storage relocation project at Dorma highlights Kardex Remstar’s professional, safe, and efficient execution—especially in high-demand production environments. It is an ideal solution for companies looking to optimize space, streamline manufacturing, and maintain a resilient supply chain.

📞 Contact us today for expert consultation on smart storage solutions, system relocation, or warehouse performance optimization tailored to your business.