Due to high demand for heat pumps, the Hoval Group has expanded production at its site in Slovakia. Among other things, an automated storage system for the manufacturer of heating and climate room solutions was installed, consisting of a pallet-high-bay warehouse, conveying technology and "AutoStore" small-parts storage. The entire new storage system, implemented by Hörmann Intralogistics as general contractor, was completed in August 2025 and handed over to customers, as can be gleaned from a press release from the intralogistics provider dated September 29.
“Hörmann Intralogistics convinced us with its overall package for the future project in Istebné during the bidding phase,” recalls Dr. Vadim Tcharnetsky, Head of Indirect Procurement at the Hoval Group. “We are pleased that, with an established and technically proficient partner, we could increase our capacity in the heat pump market.”
The "ePlant" is the largest production facility of the Hoval Group. With a capacity of up to 32,000 heat pumps per
year, it makes a significant contribution to meeting the demand for sustainable energy solutions. The project is part of a long-term corporate strategy to flexibly expand production capacities and actively shape Europe’s energy transition.
The new storage system in Istebné combines two different systems for bulk and small-parts intralogistics. The centerpiece is a three-aisle pallet high-bay warehouse in silo construction, 115 meters long, 22 meters wide and 40 meters high. It includes three automatic pallet rack handling devices, each with two double-deep telescopic forks. Another feature of the storage system is the automatic handling of system pallets as carrier pallets for finished goods.
The pallet conveyance technology enables integration of various functional areas, including inbound, the high-bay warehouse, central picking of components for production, the storage of finished goods, and the outbound goods for shipping. The in- and out-loading throughput of the system is around 100 pallets per hour.
The AutoStore system grid is 85 square
meters in size
Parallel to the high-bay warehouse, the AutoStore system operates. The "grid" of the cube-storage system covers about 85 square meters and provides space for 3,000 containers. The fully automatic storage and picking is performed by three robots from the "Red Line" series via three connected "Conveyor" ports. In addition, a service platform with a hoist crane system mounted underneath and an electric chain hoist for a combined workstation in the picking area was installed.
The material flow is supported by various software solutions: The plant control and visualization for the pallet handling devices, the conveying technology and the AutoStore system receive their orders from Hörmann Intralogistics’ Warehouse Management System HiLIS, which synchronizes the two automated storage areas and improves material flows for the combined picking workplaces.
The construction phase at Hoval was divided into five sections:
- Installation of the AutoStore system including the WMS HiLIS. The later integration with the high-bay warehouse, production and conveying technology was taken into account.
- Erection of the shelf steel structure with roof/wall cladding and sprinkler system for the 3-aisle high-bay warehouse.
- Installation of the pallet rack handling devices; Hörmann Intralogistics synchronizes all suppliers in this phase. “In the high-bay warehouse, for example, the upper guide rail of the RBGs is installed by the steelwork supplier, the lower by the RBG supplier. We act as the general contractor like a choreographer,” explains project manager Pascal Omlor. Subsequently follows the installation of the conveying technology and its connection to the HRL.
- Activation of the system by the WMS and plant control. Drive elements are tested, addressing configured via PLC, automatic operation started. The WMS HiLIS manages the interplay of all components.
- During the final commissioning, the system is brought online, performance indicators are checked, tests are conducted. Training of the staff completes the commissioning. Even after handover, Hörmann Intralogistics remains available 24/7 with its customer service.
