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Dexion AutosatSatellite Storage System

Dexion Adjustable Pallet Racking

Dexion is the specialist for customized and efficient solu-tions in warehouse logistics. With our many years of experi-ence in warehouse technology and a continuous exchange of views with our customers, we are constantly developing and refining our products – in terms of engineering, quality and design.Our aim is not to sell you a ready-made system but to work with you in developing a tailor-made and variable warehouse solution that meets your needs exactly.

The Premierack pallet racking system, with its flexibility and extensive accessories, easily adapts to meet your needs and for this reason, is the very best solution for both static and dynamic pallet storage.From standard wide aisle, through narrow aisle and high bay options to live storage, multi-level racking, mobile racking and satellite storage our systems provide the ideal solution.

Satellite Storage System

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The satellite System automates picking in the drive-in channels of the warehouse.Satellite pickers avoid damages on the racking system, compared to forklift trucks entering drive –in channels.Automates the storage of high density lanes, allowing the maximum use of a warehouse cube. Entering with a forklift truck in a static storage drive-in channel requires a lot of ability, time and concentration and can cause rack and product dam-age. DEXION AUTOSAT™ allows for all the operations to take place without going inside the rack, as all the movements are sent via a radio remote controller.

• Higher throughput than other high density systems• Higher occupancy rates are achievable• Spacing between loads can be adjusted with maximum precision• Able to work in either FIFO or LIFO system• Can be used in cold and frozen storage environment• No specialist equipment• Autopower-off feature to improve battery life• Easy to use and to maintain• No limitations in depth of storage

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Satellite Storage Systems

01 Satellite storage system02 Satellite storage system in cold environment

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About the Dexion Autosat - Satellite System

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Dexion Autosat was born of the cooperation between Dexion Storage Solutions, a producer with over 50 years experi-ence in making high quality storage systems and Automha Italy, one of the most important European producers of auto-mated storage solutions.

With a standard forklift truck you can put Dexion Autosat in either side of the racking system. Dexion Autosat recognizes the right direction: Retrieving and storage functions are completely automated. Thus it is very simple to use, the shuttle being positioned on the rails and than controlled by remote control.While the push-back systems are limited to a short depth of the channel (6-8 pallets deep) and the only suitable system is LIFO, the satellite system can work with an unlimited depth of the channel and can work both in FIFO and LIFO mode.The satellite system is especially recommended for cold and frozen environment and represents the preferred choice of companies storing food and pharmaceutical products. The satellite system was developed by Dexion together with its partners in order to cover the lack of solutions between the gravitational systems and the drive-in, offering the best mix of performance and quality in situations where the existing solutions are either not cost-effective or even impossible to implement.

The satellite shuttle is offered in variants for different types of pallets and different weights, from 1000 to 1500 Kg capacity. There are also special versions for unusual environments, such as those under -30 degrees Celsius, and other functions can be implemented at the client’s requests.

Satellite Storage System

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• Question: Where do you recommend this solution?• Dexion Expert: This solution is recommended for both cold storage and for regular temperature warehouses. It is

recommended when the customer has small to average storage space and requires for the storage capacity to be maximized. The Satellite Solution can be used both in LIFO and FIFO mode. It is suitable for pallets sized: 800 x 1200 and 1000 x 1200 mm.

• Question: In what fields of work can it be used?• Dexion Expert: The Satellite System is suitable for Manufacturing ( Food & NonFood ), Logistics & Warehousing,

Beverage Production, etc. Generally the solution is recommended for customers that wish to store 2-3 different types of product that generally have a short storage time, depending on the customer’s in-out flow, the valability period of the products, the number of work orders in correlation with the number of deliveries to final users.

• Question: What makes this system different from other high density solutions, such as Drive-In?• Dexion Expert: a) The satellite storage system is an automated system, in comparaison with Drive-In, where the stor-

age process in realized 100% by the human operator. b) Flexibility and time efficiency: The satellite System has greater flexibility than Drive-In: far shorter handling time for the Satellite; great precision in arranging the distance between pallets, the ability to rearrange the the pallets on the racking according to the customer’s needs, all of the satellite manouvers are done by using a remote control; it has an automated stop function, which leads to increased life for the battery. • Question: What are the advantages of the Satellite System?• Dexion Expert: Great handling speed, high occupancy rate (80%); easy adjusting of the distance between pallets, can

be used in both FIFO and LIFO mode, can be used both in cold and normal temperature storage conditions due to its different outfittings, easy to use and maintain, very short time for battery change (approx. 1 minute), work period of the battery - 8-10 hours continuous work, etc.

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The Dexion Expert - Why choose the satellite?

The Dexion Expert -Why choose the satellite?

• Question: When isn’t the satellite system recommended?• Dexion Expert: a) When the pallets used by the customer are in a bad shape (rotten, broken or incomplete) b) When the stored merchandise hangs over the pallet, which can cause problems in the correct func tioning of the shuttle (Eg. the imposibility of using the movement sensor, the likelihood of hitting the stored merchan dise and destroying it, etc.) c) When the customer wishes to use the system for a varied range of products ≥ 4-5 types of products.• Question:What is the typical satellite customer?• DE: The customer that understands its utility, who knows how to differentiate between an automated system and a

standard one, who understands the benefits of such a system and estimates the time in which the investment will be recovered, who understands the value of each square meter of storage space and wants his avalable space to be optimized to the maximum

SAVE TIME + SAVE SPACE = SAVE MONEYWith the satellite’s aid you can save time and space, which in the fast-moving world of logistics means saving money.The time-saving is obvious, the time needed for the forklift truck to enter the storage channel is eliminated, so the time needed to position the pallets perfectly, and in the “auto-retrieval” mode, the storage can be done automatically, thereby increasing the speed substantially.The space-saving is also important, this system eliminating a great portion of the access aisles for the forklift trucks and offering a high density for the effective storage space.

Satellite Storage System

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General Description

AUTOSAT® is a machine, powered by a lithium ion battery, which allows storage of materials loaded onto a pallet in a drive-in shelving system. Positioned in a channel, it can pick-up, deposit and re-organise the pallets with great precision.

UP position (High)DOWN position (Low)

ON/OFF button

Laser stop system

Safety system

Lithium battery

Buffers

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AutoSat Models and Versions

AUTOSAT MODELS AND DIMENSIONSModel Load

max KgDepth pallet mm

Width pallet front mm

A mm B mm C mm Stroke mm

Weight Kg

SAT.0812.ST.LTH 1500 800 1200 878 174 955 45 180SAT.1012.ST.LTH 1500 1000 1200 1078 174 955 45 200SAT.1212.ST.LTH 1500 1200 1200 1298 174 955 45 220SAT.4840.ST.LTH 1500 1220 1016 1298 174 828 45 210SAT.4048.ST.LTH 1500 1016 1220 1078 174 955 45 200

AUTOSAT versionsST = Standard: AUTOSAT® for use at room temperature (from +0°C to +45°C).BZ = Below Zero: AUTOSAT® for use in refrigerated environment (from -1°C to -30°C).

AUTOSAT is supplied as standard with:N°. 1 AUTOSAT® N°. 1 Radio control with battery chargerN°. 1 Battery charging station N°. 1 Battery unit (on board)N°. 1 Complete user manual N°. 1 Wooden crateN°. 2 Towing eye-bolts

WarrantyAUTOSAT® has a 12 (twelve) month warranty from the date of issue of the transport documentation or 60,000 missions performed by Autosat.

Satellite Storage System

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The maximum capacity of AUTOSAT is 1500kgDexion does not assume any liability regarding incorrect use of the equipment.

AutoSat Dimensions

Shuttle performances Speed with load on board ~ 30-33 m/minSpeed without load on board ~ 63-66 m/minWorking range 10-12-16 hBatteryType Lithium-Ion MNCVoltage 24 VCapacity 53 AhWeight ~ 13 KgCharging station power EU 240/50 Vac/Hz

US 115/60 Vac/HzCharging time at 20°C for 80% level 3 hCharging time at 20°C for 100% level 5,5 hBattery life with correct use min. 500 chargesBattery quantity on board 1FeaturesWorking temperature ST: from +5°C up to +45°C

BZ: from +4°C down to -30°CColours chassis RAL 6032

lid RAL 7035MotorsTravelling power motor 700 WLifting power motor 400 WRemote controllerType Radio-frequencyDisplay LCD 16x2Protection IP65Power BatteryCharging battery 500 mAh - 4,8 VMax. consumption during transmission 55 mAMax. consumption during receiving 50 mAStand-by function Stand-by mode active after 3 min. of not useBattery life (at 20°C) with correct use continuous 10 h

stand-by 1300 h

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The Remote Control

LCD

DIAGNOSTIC LED

SIREN

SELECTAUTOSAT ID

RADIO CONTROLSWITCH-ON/OFF

AUTOMATIC MODECONTROLS (Green)

MENU

COMMUNICATION ANTENNA

MANUALMODECONTROLS(Yellow)

STOP

Satellite Storage System

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Use in Cold Store

The speed of Autosat in the cold store is decreased by 20%. At full speed the formation of ice along the guide could cause the machine to slide.AUTOSAT® must always remain inside the cold store in order to prevent the effects of condensate, which can occur on the passage from the low temperature cold store to a zone with room temperature, which is higher . When Autosat is unused inside the cold store, it must be powered via the power supply unit supplied in the BZ kit in order to keep the electronicswarm. (supplied red box)Extract the battery from Autosat as shown in the figure and insert the red power supply unit.

BATTERY RE-CHARGEThe battery pack cannot be re-charged inside the cold store. The batteries can be re-charged at a temperature > +5°C.It is important to prevent the effects of condensation; dry the batteries before charging.

CHANGE BATTERYOnce the Autosat battery is flat, replace it with a charged one. It can be replaced inside the cold store.

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Optional Functions

“PUSH” COMPACTING FUNCTIONFunction operational condition:FIFO (channel operational from two sides)This function re-arranges the position of the pallets in the storage channel.

“PULL” COMPACTING FUNCTIONFunction operational condition:This function re-arranges the position of the pallets in the storage channel.

- Channel to be re-arranged:

- Channel re-arranged by AUTOSAT®:

LoadingUnloading

LoadingUnloading

- Channel to be re-arranged:

- Channel re-arranged by AUTOSAT®:

Loading Unloading

Loading Unloading

PUSH COMPACTING FUNCTION“PULL” COMPACTING FUNCTION

“PLUS” CONTINUOUS UNLOAD FUNCTIONMULTIPALLET MANAGEMENT FUNCTION

STOCK TAKING FUNCTIONCONTINUOUS LOAD FUNCTION

ANTI-COLLISION FUNCTION

Satellite Storage System

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Optional Functions

“PLUS” CONTINUOUS UNLOAD FUNCTIONThe “Plus” Continuous Unload function allows to accelerate the unload operations of the entire channel.This function replaces the standard continuous unload function.Ir can be interrupted at any time by operating on the red STOP button on the radio control

MULTIPALLET MANAGEMENT FUNCTIONTwo versions available:- MULTIPALLET FIFO- MULTIPALLET LIFOWhere enabled, the Multipallet Management function allows to store pallets of different sizes in the individual lanes of a Drive-In warehouse, precisely:- 800mm x 1200mm- 1000mm x 1200mm- 1200mm x 1200mm• Deposit, press the IN key on the radio control• Pick-up, press the OUT key on the radio control

STOCK TAKING FUNCTIONThe stock taking function allows to count the number of beds stored in the warehouse.The function is optional and can be activated by operating in the management menu of the radio control under READ PALLET. Use the FWD and BKW keys to activate and deactivate this function.Once having escaped the management menu, press the IN key to start the count.The number of pallets is displayed inside the management menu.

CONTINUOUS LOAD FUNCTIONThe continuous load function allows the operator to accelerate the material load operations in the channel.

ANTI-COLLISION FUNCTIONTo satisfy customer requirements, it is possible to insert 2 Autosats in the same channel, which move material in both directions.In order to insert 2 Autosats in the same channel, it is good practice to install the anti-collision function. Whenever the two Autosats should get too near to each other, they block inside the lane, emitting an alarm sound, thus warning the operator of the risk of collision between the two appliances.The anti-collision function is composed of a hardware component and a software component.

At the customer’s request new functions can be added to DEXION AUTOSAT.

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Quality and Standards

STANDARDS ADOPTED (AUTOSAT)

• 2006/42 Machinery Directive• 2004/108 Low VOLTAGE Directive ;• 2006/95 Electro-magnetic compatibility Directive;• EN ISO 12100-1: 2003 – Machine safety –Basic principles, main planning principles –Part 1 : Basic terminology, method (ISO 12100-1: 2003);• EN ISO 12100-2: 2003 – Machine safety – Basic principles, main planning principlesPart 2: technical principles (ISO 12100-1: 2003);• EN 60204.1 – Machine safety – Machines electric equipment• EN 13849-1 – Machine safety – Parts of the controlling system related to safety• EN 13850 – Machine safety – Emergency stop device, functional aspects-Planning principles.

Satellite Storage System

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Autosat Correct Use and Maintenance

For maintenance of the channels and recovery of Autosat from inside the shelving, Automha recommends the pur-chase of AUTOSERVICE, the Autosat maintenance trolley.

Below you can find the list of all possible uses for Autoservice:- Maintenance activity inside the racking- Autosat recovery in the event of breakdown or blockage due to external causes

AUTOSAT is a machine designed to carry wooden pallets:(EUROPALLET – BLOCKPALLET – GMA - …)It is not excluded that AUTOSAT can transport other different types of loads, such as:- CAISSONS- IRON/PLASTIC PALLETS…after communication in the preliminary stages and after sending of samples to Dexion (for system functionality test). It is important that all pallets have the stock in the centre as demonstrated in the figure.

The Loading Units are not always made up from beds and containers with regular shape. In these cases, contact our sales team, which is available to evaluate particular shapes of the loads to be handled.

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Case Study - Secret Prod

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Regardless of the number of attempts to set up a warehouse in order to save as much room as possible, we cannot be pleased unless we minimize the aisles as much as possible, in order to normally fit as much shelving as possible. This can be done by purchasing latest generation equipment with lower and lower size, but with large investment costs.The technology is evolving in the last period, by bringing highly usefull operative innovations. This way, the specialists from Dexion have brought on the market a revolutionary storage method, made up of a special racking system produced by Dexion Storage Solutions, on whose rails is fitted a satellite-shuttle, which can be controled remotely, in order to ma-nipulate the pallets for unlimited depth of the shelf, both in FIFO (First In - First Out), and LIFO (Last In - First Out) system.The pallet with the goods is positioned on the satellite, which will transfer it to the other end of the corridor. The machine’s sensor system detects the presence of the pallets and can store them with precision at predetermined distances, after which it will return to the starting position.Such a system was installed at the cold storage facility of the Romanian icecream manufacturer Secret Prod, from Braila, makers of the well-know Bonetta brand icecream. The installation was performed by a team of specialists, familiar with Dexion products. They had extensive experience in setting up different types of racking systems and had participated at an extended specialized course, referring to the installation of the satellite system.

Satellite Storage System

Type of good stored: Dairy products for icecream manufacturingLocation: Secret Prod Factory, Braila, RomaniaType of operation: LIFO, one side.Pallet dimensions: Euro Pallet: 800 x 1200.Pallet weight: 1000 Kg Pallet height: max. 1500 mm.Size: 4 blocks, 7 lanes, 14 pallets deep, 4 pallets high - in total 1568 pallet positions.

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The system is based on a Dexion Autosat - Satellite Storage System design, sold together with the shuttle manufactured by the Italian company AutoMha.The satellite system is sold as an alternative to drive-in and/or live storage systems.Latest model of shuttle equipped with laser sensors was used. ION MOS® is a leading company on the Romanian market, providing complete solutions for the meat industry (www.ionmos.eu) .The company delivers blends of ingredients to prepare meat products.Ion Mos’ mission - to best satisfy customer’s needs for ingredients and solutions while optimizing processes and delivering extra value.As a modern, innovative and technology-savy company, Ion Mos needed a specific storage system, to best fit its storage and product handling needs.

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Case Study - Ion Mos

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Type of good stored: Solutions and ingredients for meat productsLocation: Ion Mos Factory, Ilfov, Dragomiresti Deal, RomaniaType of operation: LIFO, one side.Pallet dimensions: Euro Pallet: 800 x 1200 ( Entry – 1200 mm ), Fin Pallet: 1000 x 1200 ( Entry – 1200 ).Pallet weight: 1000 Kg on each location. Pallet height: 1700 – 2000 mm.Size: 5 lanes, 3 levels high, length of line: 15 meters; 17 Euro Pallets per level or 14 Fin Pallets per level; could be mixed; special colour – red – RAL 3020.

Case Study - OSM Krasnystaw

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Satellite Storage System

Type of good stored: Various dairy productsLocation: Krasnystaw’s two warehouses in PolandType of operation: LIFO, one side.Pallet dimensions: Euro Pallet: 800 x 1200.Pallet weight: 600 Kg in Warehouse 1 and 700 Kg in Warehouse 2.Pallet Height: 1450 – 1800 mm.Warehouse 1: 12 lanes, 12 pallets deep, 226 palletsWarehouse 2: 13 lanes, 6-10 pallets deep, 288 pallets

A Dexion satellite installation was also selected by the Polish dairy-product company OSM Kransnystaw. In order to help improve the storage in their two warehouses, they chose a Dexion solution made up of Premierack racking systems provided with two, latest generation, Autosat shuttles.

OSM Krasnystaw is a modern company cooperating with nearly 300 distributors of dairy products in Poland and over 10,000 milk providers from 23 districts. The company employs about 1,000 workers and processes 160 million liters of milk annually. The company has almost 100 years tradition. The roots date back to the beginning of the past century, when on 3rd October, 1913, the Dairy Cooperative in Krasnystaw was established.In 2003 the company merged with OSM Lublin, and a year later with Zamojska Spółdzielnia Mleczarska, becoming the largest producer in the region and one of the top ten in the country.OSM Krasnystaw incessantly invest in development, introducing new solutions and modern technologies to improve the manufacturing process and ensure the highest quality of products and their competitiveness on the dairy products market. Manufacturing is fully automated: modern machines and computers control the process of turning milk into final products - cream, cheese or yoghurt, and automatic lines pour and package them for shipping.The company’s manufacturing centers are ISO certified, allowing them to sell various dairy products, and especially pow-dered milk to Asia, Africa, South America and Europe.

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Dexion GmbH Dexion Strasses 1-535 321 LaubachGermanyTel. +49 640 58 00 Fax. +49 640 58 02 06 sales@dexion.dewww.dexion.de

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For more information, please contact your local Dexion office.