Another successful project between Kärcher and io
Heidelberg, 31/03/2025
Supported by io, Kärcher brought a new fully automated high-bay warehouse into operation in Obersontheim in the district of Schwäbisch Hall at the beginning of the year. This storage solution optimizes the production supply for the hot and cold water high-pressure cleaners and steam cleaners that are manufactured in the factory and destined for consumers and commercial users.
The world’s leading provider of cleaning technology and a brand that is recognized across all industries, Kärcher is pursuing an ambitious growth strategy with currently 170 subsidiaries in 85 countries around the world. Part of this development is the continuous expansion and optimization of production at the production sites. Kärcher is investing in the future with a new high-bay warehouse at its Bühlertal plant.
As a long-standing partner of Kärcher, io has accompanied this challenging logistics project from the initial concept phase through to realization, thus making a significant contribution to improving the efficiency and sustainability of the logistics processes at the world’s largest Kärcher production site.
io has supported Kärcher from the very start of the project in September 2021 in all phases, from concept development to detailed planning, tendering and awarding, right through to implementation and acceptance. The state-of-the-art facility offers capacity of more than 29,000 storage spaces for pallets and grid boxes and plays a central role in automating and ensuring efficient processes at the Bühlertal site.
Technological excellence for maximum efficiency
The high-bay warehouse, 120 meters long, 38 meters wide and 28 meters high, extends over 15 storage levels. The highly automated storage and retrieval system enables a peak performance of up to 180 load carriers per hour. The five storage and retrieval machines are supplied by 190 meters of pallet conveyor technology and 130 meters of electric floor conveyors. Eight electric floor conveyor vehicles ensure a smooth flow of materials.
“This high-bay warehouse is a flagship example for the excellent planning and realization that io implements for its customers. We optimize logistics processes with state-of-the-art technology and sustainable designs, helping companies to improve their competitiveness,” emphasized Christian Schindler, Project Manager and Senior Consultant at io.
Sustainability and looking to the future
Alongside technological excellence, the project maintained a keen focus on sustainability. The reduction in the need for transportation between the external warehouses and the Bühlertal plant leads to a significant reduction in CO2 emissions. “The new automated high-bay warehouse is an important milestone for our largest production site in the world. We are investing €16 million in innovation and sustainability to optimize our logistics processes and save 150 tonnes of CO₂ per year. A sincere thank you to everyone involved, especially to our project team and io for the cooperative partnership we have enjoyed over the last few years,” said Hartmut Jenner, Chairman of the Management Board of Alfred Kärcher SE & Co. KG at the inauguration ceremony.
Successful partnership with Kärcher
The successful implementation of this project illustrates the strength of the long-standing partnership between io and Kärcher. “From initial strategy development to successful commissioning, we were able to guide Kärcher as a reliable partner. The result is a tailor-made high-bay warehouse that offers maximum efficiency and future-proofing,” emphasizes Christian Schindler.
“The successful commissioning of the high-bay warehouse represents a significant highlight in the close and cooperative partnership between our two companies. In recent years, we have already had the opportunity to support Kärcher in planning and implementing the expansion of the high-bay warehouse at the Global Parts Center in Obersontheim and in realizing the new Kärcher Service Center in Ahorn,” adds Frank Czaja, Business Unit Manager Logistics at io.
The high-bay warehouse was officially put into operation with the ceremonial handover of the system signage. io looks forward to further cooperation and future innovative projects with Kärcher.
About Kärcher
Kärcher is the world’s leading supplier of cleaning technology. The family-owned company employs 170 people in 85 countries and over 17,000 subsidiaries. The company achieved sales of €14.27 billion in the 2024 fiscal year.
