How a central warehouse is reorganising production and dispatch
3,500 tonnes of aluminium profiles per year, material lengths of up to 7.5 metres and limited storage space: TIR Technologies needed a logistics system that could keep pace with its growing production. Two UNIGRIP automatic honeycomb storage systems, the intelligent KASTOlogic warehouse management system and a KASTOfenestra station now bring structure to the material flow. The profiles are stored safely, stock levels remain transparent and the right materials are reliably available for the manufacture of awnings and pergolas.
The challenge: increasing storage capacity within a limited space
The large volumes of material and profile lengths of up to 7.5 metres placed significant demands on TIR Technologies’ internal logistics. Manual handling and checklists created additional work and increased the risk of errors. At the same time, the profiles needed to be stored in a dry and protected environment and be available for production at any time, allowing for reliable planning.
Awning production was particularly challenging: within the specified space, cassettes for 6-metre and 7.5-metre-long profiles had to be accommodated within a single system. This called for a solution that made efficient use of the available space and handled both types of cassette safely.
The solution: automated honeycomb storage systems and intelligent profile handling
KASTO has developed an automated storage and material flow concept in collaboration with TIR Technologies. An initial UNIGRIP-type honeycomb storage system with 1,200 storage locations supplies the pergola assembly line. A second system, situated at a height of 13 metres, provides 2,000 storage locations for awning production.
Storage and retrieval operations are controlled by the KASTOlogic warehouse management software. In addition, KASTOfenestra align ensures the precise, ergonomic and continuous transfer of the profile racks.
Project highlight: Two types of bin, one storage and retrieval machine
The second UNIGRIP honeycomb storage system performs a technically demanding dual task within a minimal footprint: a single storage and retrieval machine handles cassettes for 6-metre and 7.5-metre-long profiles on opposite sides. A dual sensor system detects the cassette type and position and provides the data required for precise braking manoeuvres and a safe handover.
The KASTOfenestra align recirculation station complements the concept with a centring aid, hydraulic lowering and two cassette stations, ensuring a material flow without unnecessary waiting times.
Providing Profiles with Precision
Managing 3,500 tonnes of aluminium profiles each year demands a logistics system that can keep pace. TIR Technologies, a specialist in sun shading solutions, has systematically automated its warehouse processes, resulting in increased space, transparency, and flexibility. By implementing KASTO intelligent storage technology and an industry-specific KASTOfenestra station, the company has achieved improved material flow, enhanced ergonomics, and greater productivity, demonstrating how these elements go hand in hand.
The numbers speak for themselves: Each year, TIR Technologies handles and processes tonnes of aluminium profiles measuring up to 7.5 metres in length. This French company, located in Kilstett, north of Strasbourg, has been manufacturing sun shading solutions—including awnings, pergolas, blinds, and roller shutters—for over 20 years. With a workforce of 330 employees, TIR achieves an annual turnover of 110 million euros, reflecting a significant volume that places high demands on its logistics operations.
To enhance production support and leverage improvement opportunities, TIR Technologies has been utilising automated storage systems and industry-specific solutions from KASTO since 2019. Currently, two systems are in operation, internally referred to as "KASTO 1" and “KASTO 2.”
KASTO 1 is a UNIGRIP honeycomb storage system that has 1,200 storage locations, reliably providing the pergola assembly with the necessary profiles. In 2022, KASTO 2 was introduced as an additional automated honeycomb storage system of this type. The system includes 2,000 storage locations, rising to a height of 13 metres, and manages the aluminium profiles used in awning production. A unique feature of the KASTO 2 system is its ability to handle a technically demanding task: it simultaneously manages two different types of cassettes within a compact space using just one operating gantry crane (OGC).
The transition to automated honeycomb storage has brought significant benefits to TIR Technologies: These systems enable the storage of twice the volume of aluminium profiles within the same space by effectively utilising vertical storage. This optimisation maximises the available capacity. Every incoming and outgoing transaction is automatically recorded, eliminating the need for time-consuming lists and manual transfers. As a result, the potential for errors is greatly reduced, which significantly eases employees' workloads. Additionally, the profiles are stored in a dry, protected environment and are always ready for use in the next production phase.
The KASTOlogic warehouse management software is the brain of the warehouse operations: It coordinates the handling of incoming and outgoing goods, optimises travel paths, monitors the flow of materials in real-time, and ensures that production runs smoothly, safely, and efficiently. This software transforms efficient materials handling into a true competitive advantage for TIR Technologies.
Precision through sensors and control
Adapting KASTO 2 to meet the specific requirements of the project involved significant development work in both the mechanical system and software. The operating gantry crane for the UNIGRIP honeycomb storage system is designed to handle profiles that are 6 metres long in cassettes on one side and 7.5 metres long on the opposite side.
A dual-sensor system on the operating gantry crane identifies the specific type of cassette and its precise position. This information is essential for accurate braking operations and the safe transfer of loads. Additionally, KASTO’s engineers adjusted the reference points and the gripper movement cycles to reliably map out various travel paths along the transport chain.
Patrick Barbier, IT Manager at TIR Technologies, explains: “Thanks to this customised solution, we were able to implement a storage system that would not have been feasible otherwise within the available space. Additionally, the automated system allows us to achieve significantly more efficient production, making it easier to plan.”
When profiles know where they belong
Material flow is not random. An intelligent system is essential to ensure window profiles arrive precisely where they are needed, keeping everything in sync. KASTOfenestra align fulfils this function: as a central rotary station for the storage and retrieval of profile materials. It keeps processes moving safely, with precision, and without unnecessary delays.
The benefits are apparent from the moment the customer's racks are placed down. An integrated horizontal centring aid, positioned at a height of two to three metres, guides each rack effortlessly into the correct position. Forklift operators can place the racks without needing to reposition or manoeuvre the forklifts – quickly, consistently, and with minimal effort. Storage can be performed either manually using a positioning stop or automatically with a manipulator. Hydraulic lift units then take over, lowering the customer's rack in a controlled manner until it is precisely positioned in the cassette.
To ensure a smooth flow of materials, KASTOfenestra align is equipped with two cassette locations. While racks or packages are being stored, the next location is already prepared, eliminating waiting times. This station is customised to accommodate the customer’s existing racks and integrates seamlessly into current intralogistic processes.
Whether in window, door, or curtain wall construction, or in related sectors such as awnings, pergolas, or roller shutters: KASTOfenestra solutions ensure efficient picking, preparation, storage, and retrieval of profiles of varying lengths and shapes, enhancing both order and speed.
Automated storage solutions, like honeycomb and overhead storage systems, are essential for creating structured and space-saving processes. By integrating these systems directly into the production line, they ensure that the appropriate profile is available at the right time for each stage of the processing.
From initial concept to commissioning
The collaboration between TIR Technologies and KASTO is focussed on technical expertise and practical solutions. KASTO effectively met the requirements by providing customised systems and a well-structured project approach. The planning, implementation, and commissioning stages were carried out in a coordinated manner, with close consultation between the two companies.
The close proximity of the two sites has proven to be an advantage: The KASTO plant in Achern is located just about a 30-minute drive from the production site in Kilstett. This allows for quick resolution of technical issues and efficient coordination of processes. “From the very beginning, KASTO has been instrumental in helping us enhance our profile handling capabilities with a clear focus,” says Patrick.
Material flow optimisation
The two KASTO systems serve as the foundation of a comprehensive and well-designed logistics concept at TIR Technologies. Material flows are meticulously managed to avoid bottlenecks, and processes are organised efficiently. One significant advantage is apparent during delivery: the aluminium profiles are now stored securely in the automated storage system, which eliminates the need for complex packaging of raw materials. This simplification makes deliveries easier and more cost-effective for suppliers, directly enhancing efficiency at TIR. Additionally, the reduction in packaging materials contributes to sustainability efforts by decreasing waste, lowering transport volumes, and reducing resource consumption, benefiting both the environment and the entire supply chain.
Key factor for production: The automated systems and the KASTOfenestra station, which allow for the planning and management of significantly larger quantities and production volumes than were previously achievable with manual storage systems. This advancement results in more stable processes, improved planning reliability, and a quicker return on investment since available capacity can be fully utilised.
The effective combination of a well-structured logistics concept, automated systems, and intelligent material handling creates an economical, reliable, and future-proof material flow. This approach sustainably supports TIR Technologies’ production capacities and enhances overall supply chain efficiency.
Perspective: Partnership with a future
TIR Technologies is continually improving its internal processes and is optimistic about future growth. The successful partnership with KASTO serves as a crucial foundation for this progress. The projects completed so far showcase how modern storage and material flow solutions can lead to greater efficiency, transparency, and process reliability.
“KASTO has demonstrated itself to be a reliable partner for us,” states Patrick Barbier. “These valuable experiences will significantly benefit our future logistics development plans.”
The partnership between TIR Technologies and KASTO remains essential for a long-term, efficient, and innovative logistics system.