Stutensee, November 11, 2020 TUP (TUP) supports the HABA family of companies in the planning and further development of warehouse management modules for the operation of the automated bag sorting system of Dematic GmbH.

The vision of fast returns processing has succeeded. The pocket sorter originally planned for this sub-process was successfully put into operation in April 2020. Now, the logistics management of the HABA family of companies sees the next goal in using the high-performance hardware to optimize order picking as well. The software manufactory supports the german toy and children’s furniture manufacturer in the expansion of its business processes and control systems, so that even common replenishment goods from the external warehouses can be buffered.

The expansion means that the 20 buffer loops, capable of holding up to 40,000 products, can not only make returns reusable for shipping in the shortest possible time, but can also be used for precautionary replenishment and for processing so-called ‘silver’ and ‘golden cartons’. The precautionary replenishment can be defined manually by an employee or can be extrapolated from existing orders in the picking process using algorithms. By means of jointly defined boundary conditions and process steps, the HABA family of companies and TUP ensure that no delays occur between the external warehouses and the picking zone, even during order peaks.

In addition, the software-supported creation of ‘Silver’ and ‘Golden Cartons’ ensures that all distribution center resources are used as efficiently as possible. A ‘Golden Carton’ requires the entire quantity of a carton for several customer orders, while a ‘Silver Carton’ requires a sufficiently large quantity from one carton. This reduces the distances travelled by employees, the necessary movements on the conveyor system and the picking effort.

The warehouse management system was adapted to the requirements of the HABA family of companies in order to control the consolidation of the articles in the packing department.

TUP already accompanied the integration project of the Omni Channel Fulfillment solution of the automation technology provider Dematic as co-planner and consultant from the initial planning to the commissioning, in order to integrate the new technology into the already extensively used distribution center together with all project partners involved. The software manufacturer focused on optimizing business processes throughout the distribution center in order to integrate returns processing via the bag sorter system into the existing architecture as efficiently as possible.

The TUP GmbH & Co. KG (TUP) is a medium-sized family business based in Stutensee, around 15 kilometers northeast of Karlsruhe, which plans and implements customized, modular intralogistics solutions.

For interview requests you can reach your contact Peter Klement via or by phone via +49 721 7834 194. The complete company profile can be found on this page.

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