Clark Materials Handling’s electric forklifts help ensure emission-free logistics at a door and gate factory in Germany.
In Großzöberitz, Saxony-Anhalt, door and gate manufacturer Teckentrup produces steel doors and frames on one of Europe’s longest production lines. Around 1,500 to 2,000 doors roll off the production line every week. This requires a logistical masterpiece every single day. A total of 30 Clark electric forklifts, which prove their worth in all areas of the factory, make a significant contribution to this. The Clark fleet is a prime example of how emission-free, low-maintenance handling can be successfully implemented in industrial door production.
Teckentrup GmbH & Co. KG, headquartered in Westphalia and with production facilities in Saxony-Anhalt, is one of the largest manufacturers of doors and gates in Europe. As an expert in customised door and gate solutions, Teckentrup offers high-quality, customer-focused products in the home (garage doors), professional (functional doors) and industrial (industrial doors) sectors. The company works with its partners to develop tailor-made solutions and enjoys both national and international success.
Industrial customers
Teckentrup currently has a high vertical range of manufacture of 90 per cent. With around 900 employees and a network of European subsidiaries and partners, the company has extensive market knowledge and develops doors that are precisely tailored to country-specific requirements. The focus is on the development and production of high-quality industrial doors and functional sheet steel doors, which are specially manufactured for use in fire, sound, burglary and smoke protection. Requirements have increased significantly in recent years due to stricter regulations and an increased need for security.
“As a medium-sized, owner-managed company, we are flexible, provide individual customer service and meet high requirements,” explains Peter Handrich, Head of Supply Chain Management at Teckentrup in Großzöberitz. “We are the market leader in terms of approval depth and technical specifications, especially when it comes to safety issues such as fire protection or special constructions.”
Digitalisation plays an important role in accelerating and streamlining work processes. “Teckentrup is driving forward digital solutions in all areas of the company, with a focus on sales and production,” explains Handrich. “Our online configurator TEO, for example, allows doors and gates to be configured quickly and in a user-friendly manner in accordance with standards, and construction projects to be planned efficiently,” he adds. “A new import function makes it possible to read, analyse and process service specifications at the touch of a button.”
High demands on functional doors
In Zörbig Teckentrup operates a factory built in 1990 and continuously modernised and expanded to produce steel doors – in particular fire doors, tubular frame doors, roller shutters and frames. “Here, industrial doors are manufactured largely automatically in two shifts,” explains Handrich. “Due to rising production figures of around 100,000 doors and 5,000 roller shutters per year, the capacity in the powder coating area at the Großzöberitz plant was expanded in 2023 with a new system and the manufacturing processes were restructured.”
Teckentrup is currently planning two new production lines for frames and a new mat hall for the manufacture of fire doors. Sustainability plays a major role: the roof of the production hall in Großzöberitz is equipped with a PV system with a total capacity of 1000 kWp for generating the company’s own electricity. When the decision was made to purchase new industrial trucks, it was clear that only environmentally friendly electric forklifts would be considered.
Sustainability and safety in the truck fleet
“We tested several competing vehicles, but I liked Clark’s ‘green’ one best and it won us over – not because of the colour,” laughs Handrich, “but because of its good performance data and high user-friendliness.” The close cooperation with Clark’s partner P&H Gabelstapler und Baumaschinen was also a decisive factor. “P&H had already provided us with good advice and support with the Clark gas forklifts,” says Handrich. Marcel Krämer, Head of Maintenance, can only agree: “The Clark forklifts and P&H have become indispensable in our factory.”
Currently, 30 Clark electric forklifts are in use in Großzöberitz – including 27 GEX 20-30 electric forklifts with a load capacity of 2 and 3 tonnes and one GEX 50 electric forklift with a load capacity of 5 tonnes and a special triplex mast with a lifting height of 8.50 metres. The vehicle is mainly used for maintenance work, for example on the PV system. Two new Clark SE20 (48 volt) and SE30 (80 volt) electric forklifts were recently purchased. With a load capacity of 2 and 3 tonnes, these forklifts offer the perfect combination of ergonomics, safety and high handling performance. The compact forklifts are very manoeuvrable and ideal for indoor and outdoor use. With a steering angle of 101° (zero steer turn axle), they prove particularly useful in narrow aisles or space-critical work areas, as they can turn almost on the spot.
Occupational health and safety are high priorities at Teckentrup. Management also listens to its employees. “Our forklift drivers should feel comfortable on their forklifts, because good ergonomics increase productivity,” says Peter Handrich. It was therefore important that the electric forklifts had an ergonomic driver’s seat and intuitive controls. Restraint systems from IWS provide additional safety. The IWS ‘Pilot Protector’ restraint system consists of gas-pressure-sprung swing doors that protect the driver in the event of the vehicle tipping over sideways.
Lead-acid instead of lithium-ion batteries
All Clark electric forklifts are equipped with lead-acid batteries. Teckentrup made a conscious decision against lithium-ion technology. “The use of Li-ion batteries is not cost-effective in our factory,” explains Krämer. “We have the time to charge batteries because our logistics operate on a single shift basis.” The site uses high-frequency charging technology so that vehicles are quickly ready for use when needed. “We have the space for the charging infrastructure. Lead-acid batteries have a long service life – often well over ten years – even with around 1,000 operating hours per year in single-shift operation,” adds Krämer.
Tailored to the task
Clark forklifts are used in all areas of the plant, from goods receipt and dispatch to truck loading and unloading. They distribute goods within the plant and supply the production lines with materials. Raw materials are delivered on coils or pallets and transported to the relevant consumption points. Larger coils are moved by crane; smaller coils and palletised goods are transported to their destination by forklift. The hydraulic fork adjustment ensures that the forks of the forklift can be adjusted from pallet to coil transport.
The material for current production is kept ready to hand at the workstations. Clark forklifts also ensure that supplies are replenished. The lead time from ordering a door solution to delivery is approximately 4-5 weeks for standard solutions. The finished doors are stored in a cantilever trolley in the warehouse or transported by forklift to the shipping department, where they are packaged. The forklifts responsible for picking the goods are equipped with a tablet so that picking can be carried out paperless via the merchandise management system.
“Our goal at our plant in Großzöberitz is to make industrial door and gate production as efficient and sustainable as possible – from resource-saving production and in-house power generation to emission-free and smooth logistics processes. Our partner Clark also makes an important contribution to this,” concludes Handrich.
In mid-December 2025, Swedish food retailer Axfood and the Witron Group signed a project agreement as well as the contract for remote and ‘OnSite’ services, thereby jointly initiating the realization of another full-range logistics centre. A 90,000 square metre highly-automated facility will be built in Kungsbacka (near Gothenburg) in southern Sweden, supplying more than 400 stores with different dry, fresh, and frozen items. On peak days, more than 560,000 cases will be picked in a store-friendly manner using fully or semi-automated processes. The new project underscores the expansion of the strategic partnership between the two companies, which have already very successfully put one of the world’s most efficient omnichannel distribution centres into operation in Bålsta (near Stockholm).
“I am glad that we now have signed an agreement with Witron for automation in the logistics centre that we will establish. This solution will give us a more flexible, efficient and sustainable logistics chain for product supply to our stores in the southern parts of Sweden, thereby strengthening the entire Axfood family’s competitiveness,” comments Simone Margulies, President and CEO of Axfood.
Logical next step
“It feels very good to have the agreement in place for this strategically important automation solution. With the experience we have built together with Witron in Bålsta, we know that this technology will give us the right conditions going forward, and as a natural step, we feel confident in continuing this journey also in southern Sweden. This investment is fundamental in strengthening Dagab’s and Axfood’s future logistics structure, and for continuing to deliver on our ambition of market-leading efficiency,” says Hans Bax, Managing Director of Dagab.
High level of automation across all temperature zones
In Kungsbacka, products will be stored and picked across three temperature zones: ambient goods (+18 °C), fresh goods (+2 °C), and frozen items (-26 °C). As in Bålsta, the solution relies on standardized Witron logistics modules, including Order Picking Machinery (OPM with a total of 37 COMs), All-in-One (AIO), the Car Picking System (CPS), and a fully automated shipping buffer. Within this shipping buffer, store-friendly picked and consolidated order pallets are buffered and provided just-in-time on heavy-duty lanes, sequenced by delivery route for efficient truck loading. In addition, the Goods-to-Person (GTP) solution enables ergonomic semi-automated picking operations in the frozen food area.
High-performance warehouse management system
The overall material flow includes more than 500,000 storage locations for wooden and plastic pallets, roll containers, totes, and refrigerated containers, 111 stacker cranes, as well as 16+ kilometers of conveyor technology. All processes are controlled by a multifunctional warehouse management system with open interfaces from the WMS to the customer’s supplier systems, route scheduling systems, and sales systems. This enables a high level of end-to-end optimization across Axfood’s entire internal and external supply chain. A Witron OnSite service team of more than 60 employees ensures consistently high system availability in multi-shift operation around the clock – 365 days a year.
Successful omnichannel project
Both companies can reflect positively on a jointly and successfully implemented project. Since early 2025, following a phased ramp-up, one of the most innovative logistics centres in the retail industry has been operating at full capacity in Bålsta, around 40 kilometers northwest of Stockholm. Axfood and Witron designed and realized a cutting-edge omnichannel distribution centre that supplies stores as well as end customers via click + collect and home delivery. The highly automated system handles a product range of 22,000+ dry, fresh, and frozen items.
In the highly competitive U.S. fashion market, logistics accuracy plays a critical role in protecting margins and meeting strict retail compliance requirements. Perry Ellis International, one of North America’s leading fashion groups, has strengthened its B2B outbound operations by deploying an automated post‑picking validation system based on RAIN RFID tunnels at its distribution centre in the Atlanta area.
The project targets one of the most sensitive points in fashion logistics: final order validation after picking and just before shipment to wholesale customers and retail networks. While picking operations were already supported by pick‑to‑light systems, final verification still relied heavily on manual checks, making it difficult to detect discrepancies before shipments left the facility.
In the U.S. fashion industry, these discrepancies carry a direct financial impact. Chargebacks caused by missing or excess items are among the most common penalties imposed by retailers, often reaching up to 20% of the invoice value and resulting in losses that can amount to tens of thousands of dollars per shipment.
To eliminate this risk, Perry Ellis implemented high-density RFID tunnels fully integrated into its existing conveyor lines. The solution automatically validates the contents of each open box after picking, comparing in real time the items detected by RFID with the expected order data.
The system combines Clustag MOT Station RFID tunnels, capable of processing up to 1,000 boxes per hour and reading up to 600 items per box, with Cognex barcode readers for box identification. Interroll automated rejection lines that divert non compliant shipments without interrupting operational flow.
The entire process is orchestrated by Zentup, Clustag’s middleware platform, fully integrated with Perry Ellis’ Manhattan WMS, ensuring real time EPC level validation and allowing only compliant orders to proceed to shipping. The entire process is orchestrated by Zentup, Clustag’s middleware platform, fully integrated with Perry Ellis’ Manhattan WMS, ensuring real‑time EPC‑level validation and allowing only compliant orders to proceed to shipping.
One of the challenges was deploying the RFID solution in a live production environment under tight timelines and complex installation conditions, including work on mezzanines over 12 meters high. Despite these constraints, the RAIN system was implemented without interrupting daily operations or reducing throughput.
The results were immediate. Since go‑live, Perry Ellis has achieved a 17% reduction in discrepancies detected after the RFID tunnels, along with a significant decrease in non‑compliant shipments reaching B2B customers. This has translated into substantial savings in chargeback penalties and improved product availability at stores, ensuring the correct sizes, colours, and styles arrive at the point of sale.
“This project shows how RFID technology can transform fashion intralogistics from day one,” says Jorge Robledillo, Director of Clustag North America. “Strong collaboration between teams was essential to delivering measurable results in a highly demanding operational environment.”
According to Tom Seow, VP of Distribution Engineering at Perry Ellis, “the RFID tunnel solutions, integrated with Zentup, allow us to detect errors before they reach the store and give us a clear competitive advantage. We will continue investing in these systems for future projects.”
With this deployment, Perry Ellis reinforces its intralogistics digitalization strategy and demonstrates how automated post‑picking validation with RFID tunnels has become a key tool for reducing financial risk, improving operational efficiency, and meeting the high standards of U.S. retail operations.
This success story will be featured by Clustag at MODEX 2026, where the company will exhibit from April 13 to 16 in Atlanta (Booth B17332). The event will serve as a platform to discuss with U.S. customers and partners how RAIN RFID solutions can be successfully integrated into highly automated intralogistics environments and how these projects are setting a new benchmark for B2B fashion distribution in North America.
Autonomous navigation and fleet management supplier BlueBotics has launched ‘SmartPass’, a new efficiency-driving innovation within its ANT software suite.
Available for ‘ANT driven’ AGVs and AMRs, SmartPass is a robust, safe, and highly configurable technology that meets the core efficiency goal of obstacle avoidance without the drawbacks of traditional AMRs. SmartPass suits all types of automated vehicles and industrial sites.
No matter how clean a site, and how well trained its staff, the paths of mobile robots sometimes become blocked… AGVs typically manage this situation by sending an alarm to an operator, while AMRs take any route possible, without limitation. The first can lead to transport delays, the second to traffic deadlocks. SmartPass effectively bridges the gap between the two.
SmartPass enables automated vehicles to follow virtual paths most of the time — for efficient, robust, and repeatable operation — while performing pragmatic obstacle avoidance maneuvers when blockages are detected.
“Rather than layering basic traffic management over obstacle avoidance functionality — which AMR producers have attempted with limited results — SmartPass does the opposite,” Tomatis explained. “It adds smart, configurable obstacle avoidance to ANT navigation’s default ‘virtual path follower’ mode. This ensures the powerful traffic management features of our ANT server fleet manager are also applied to SmartPass maneuvers.”
Three key SmartPass benefits
ANT’s SmartPass function offers three key benefits that together are unique in the mobile robot industry:
Efficiency-focused movement • Vehicles using SmartPass take the shortest route around an obstacle — within pre-configured limits — before returning immediately to their virtual path. • SmartPass-enabled vehicles also move faster than traditional AMRs. Travelling at optimal speeds and with optimal acceleration, they follow virtual paths and respect clear traffic rules most of the time, switching to slower, more reactive speeds only when needed. • Vehicle actions like moving forks and communicating with equipment take place during SmartPass maneuvers, saving time versus the more common sequential approach. • SmartPass maneuvers are blocked near pick/drop points to guarantee precision.
Minimizes deadlocks • By managing the movements of vehicles within the ANT server’s existing traffic management framework, SmartPass guarantees that vehicles only avoid obstacles when there is no risk of blocking another robot, minimizing the chance of deadlocks. • Vehicles only move around objects and never around other vehicles, a further cause of deadlocks.
Fully configurable • SmartPass can be configured to suit every user’s site and operational needs. Customers can define, for example, the maximum distance a vehicle is allowed to travel from its virtual path; the areas (and even individual routes) of a site where SmartPass cannot be used; and vehicle-specific parameters such as the exact distance to stop before an obstacle.
“SmartPass doesn’t allow robots to roam freely, and it is built from the ground up on ANT server’s powerful traffic management, virtually eliminating the chance of deadlocks,” Tomatis added. “We are confident this safe, prudent approach best meets the needs of industrial customers looking to deploy AGVs and AMRs in what are often high-traffic locations.”
SmartPass is available now for vehicle makers, system integrators, and end users deploying ‘ANT driven’ AGVs/AMRs managed by BlueBotics’ ANT server fleet manager.
Scott Saunders (pictured, below), Technical Manager at Watco UK, shares his expert advice on preventative maintenance, floor care, warehouse floor paint and operational best practice to help logistics and distribution centres maintain a strong footing throughout 2026 and beyond.
What advice would you give to facilities managers who want to take a more proactive approach to maintenance and repairs this year?
“The key is to not wait for minor issues to become major problems. Seasonal changes, particularly the colder, wetter weather in winter, often leads to damage and hazards. Scheduled inspections and checklists for floors, steps and drainage points can prevent costly accidents and disruption.
“Using the right materials from the outset also makes a huge difference. Durable industrial floor coatings, e.g. Watco’s ‘Epoxy Gloss Coat’ help protect high-traffic areas, while anti slip coatings such as our ‘Safety Coat’ can be applied to the floor around entrances, ramps and wash-down zones to reduce slip risk from surface water. For small areas of surface damage, fast-setting repair solutions allow teams to carry out repairs quickly and get areas back into use with minimal downtime.”
How should warehouse layouts be reviewed to improve safety and flow efficiency? Is zoning essential?
“Warehouse layouts should be reviewed regularly, especially when operations change or new equipment is introduced. Many sites evolve organically over time, which can create pressure points where pedestrians, forklifts and automated vehicles meet. These areas not only slow operations down but also increase the risk of collision accidents.
Factory background with concrete floor, night scene.
“I do believe that zoning is essential for safe, smooth-running facilities today. Introducing clear pedestrian paths, and categorising facility areas based on usage e.g. parking bays and storage areas helps to ensure clear boundaries and safer behaviour.
“We offer both paint and tapes for teams to identify whether they want to line mark a boundary on the floor, or paint the whole section in a designated colour for illustrating zones. Watco’s ‘Epoxicote High Build’ and ‘Safety Tapes’ are ideal for defining zones quickly and clearly as they can be applied with minimal operational disruption. Observing how people and vehicles actually move through the warehouse is also important; layouts should reflect real-world use, not just plans on paper.”
How can health & safety costs in warehousing be monitored and evaluated?
“Many operators focus on direct costs such as PPE or training, but the indirect costs can be far greater. Lost time, damaged goods, insurance claims and reputational impact all add up quickly. Tracking near-misses, minor injuries and urgent repair requests provides valuable insight into underlying issues and helps prioritise investment.
“For example, repeated floor repairs in the same location often indicate that a more permanent solution is needed. Logging defects, repairs and associated downtime allows operators to identify trends, justify preventative spend and, over time, reduce both maintenance demands and overall health and safety costs.”
How do you recommend FMs get on top of flooring inspections and repairs?
“The most effective way to get on top of flooring inspections and repairs is to build them into everyday routines. Assigning responsibility for inspections e.g. a checklist that is tackled by a rota, ensures issues are spotted consistently, not just when problems become obvious.
“Inspections should focus on high-traffic routes, loading bays and areas exposed to moisture or chemicals, with findings logged so recurring issues can be tracked and prioritised. Smaller areas of surface damage such as hairline cracks, loose edges or shallow holes should be addressed quickly, before they develop into larger, more disruptive repairs.
“Planning for frequent, small-scale repairs also makes a difference. Using fast-curing repair materials allows work to be carried out in live environments with minimal disruption, which removes one of the main barriers to acting early.”
Warehouse floor paint
We talk a lot about warehouse automation, but many distribution centres are still untidy and cluttered. How can that be avoided?
“Automation doesn’t remove the need for good housekeeping – in fact, it makes it even more critical. Automated systems rely on clear routes, smooth floor conditions, and well-defined zones. Cluttered floors, damaged markings or poorly stored pallets can quickly undermine the benefits of automation.
“Avoiding this comes down to culture and clarity. Visual management, such as clear line markings and signage reinforces expectations. Temporary overflow should not become permanent, and regular audits help maintain standards. When staff understand the ‘why’ behind keeping areas clear, compliance improves and automated systems can deliver maximum value.”
How much downtime is typically involved in line marking, re-painting, matting, and taping work in warehouses?
“Downtime is often the biggest concern, but modern materials and methods have reduced disruption dramatically. Many line marking paints and floor coatings are fast-curing and can withstand traffic within two hours. Work can also be phased or carried out in quieter shifts to minimise operational impact.
“Similarly, high-quality matting and surface treatments can be installed quickly, providing immediate safety and efficiency benefits. The short-term inconvenience is minor compared to the long-term gains: reduced accidents, fewer urgent repairs, and a more productive warehouse.”
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