Future-proof retrofit/upgrade
The project includes the replacement of existing conveyors, an expansion of sorting capabilities, and the addition of an extra level of shelving above the mezzanine. Furthermore, the conveyors leading to the packing stations are being renewed, and an automated packaging machine is being integrated. In addition, the system’s controls and software are being updated. Although a large portion of the existing installation is being replaced, the core of the system remains intact. As such, the project constitutes a retrofit and upgrade of an existing intralogistics system.

Upgrading step by step
A retrofit in an operational logistics environment requires a different approach than the implementation of an entirely new system. After all, the existing system cannot simply be shut down for an extended period. For this reason, the work is carried out in phases.

“The greatest challenge lies not so much in the technology itself, but in the fact that everything must take place while operations are ongoing,” explains Marc Biermann, Head of Sales Engineering at Inther. “We therefore collaborated on an approach that allows us to replace the system step by step. During scheduled intervals, we dismantle a portion of the installation and construct the new section in its place. By the start of the following week, that part is ready to be put back into operation.”

This phased approach ensures that the work can be performed without interrupting logistics operations. The first components of the upgraded system are already live, and the entire project is expected to be completed in the first quarter of 2027.

Collaboration is key to success
“A retrofit like this is all about thorough preparation and seamless collaboration,” says Bas Maas, Project Manager at Inther. According to Maas, this collaboration is a crucial factor in the smooth execution of the project, as various tasks must be constantly coordinated. “To our mutual satisfaction we work together effectively. DHL is highly proactive and flexible, for instance when the process needs to be temporarily halted. We handle as much preparation as possible during the week, allowing us to carry out targeted modifications during scheduled weekend slots. If necessary, we are also granted specific time slots during the week to perform work, after which operations resume.”

Trust built over fifteen years
This retrofit builds upon a partnership that began fifteen years ago. The original system needed an upgrade, partly because various components and software elements had reached the end of their technical lifespan. At the same time, the logistics partnership between DHL and its client was extended and expanded, creating a need to adapt the installation to accommodate future operations and increased volume.

“It is highly valuable that, after some fifteen years, we are once again involved in upgrading the system,” says Biermann. “We are familiar with the installation, the processes, and the interfaces. Especially in a retrofit that must be implemented step-by-step within an existing operation, this knowledge helps keep the transition manageable.”

Once the retrofit is complete, DHL will have an upgraded and expanded intralogistics system, with minimal impact on daily operations throughout the project.