Kardex Polska Sp. z o. o., acting as general contractor, is building a 3-aisle, fully automated high-bay warehouse in Kędzierzyn-Koźle for the manufacturing company Jokey Poland Sp. z o.o. The warehouse has a capacity of 8,616 pallets and can handle up to approximately 200 pallet operations per hour.
Jokey packaging is part of everyday life - from the paint that colors our homes to the dairy products we enjoy daily. Portfolio of products includes a wide range of innovative and reliable food and non‑food containers, high‑quality components, and pharmaceutical jars. Every Jokey product is designed and manufactured entirely in‑house, combining decades of expertise with cutting‑edge technology.
To continue delivering the highest level of service and meet growing market expectations, Jokey Poland is investing in an advanced automated high‑bay warehouse. This strategic development strengthens their commitment to sustainable efficiency, seamless logistics, and outstanding supply reliability.
Fully automated high-bay warehouses (HBWs) are a key component of modern intralogistics. One of their key advantages is the ability to accommodate a maximum number of loading units in a limited footprint by optimally utilizing available height. On a mere 2,484 square meters (108 x 23 meters), the general contractor, Kardex Polska Sp. z o.o., is building an automated warehouse nearly 20 meters high with 8,616 pallet spaces for storing finished goods, such as plastic packaging, on EUR pallets.
For a global packaging manufacturer, this will be the first fully automated high-bay warehouse project in Poland. To ensure maximum capacity, efficiency, and effectiveness of warehousing processes, the project is being implemented and is expected to be completed by the end of 2026.
The technology designed and implemented by Kardex Mlog will significantly reduce the manual work involved in storing and retrieving goods, transforming previously labor‑intensive manual tasks into efficient, automated operations.
The high standard of sustainability is underscored by the photovoltaic installation installed on the roof. It generates a significant portion of the energy needed to operate the three-bay high-bay warehouse.
The key components of the system are three Kardex MSingle A-450/19-ZT automated pallet stacker cranes. This designation indicates a load capacity of 450 kg (although the maximum load capacity of this type of machine is 1,200 kg) at a height of 19 m and double-deep storage (ZT). The installation is equipped with a conveyor system with over 150 drives and two automatic transfer vehicles in the outbound area. Three different load units based on the dimensions of the EUR pallet can be transported, stored, and retrieved fully automatically: wooden pallets according to the DIN EN 13698-1 standard and two types of plastic pallets, which was necessary to maintain the client's existing logistics processes.
Pallets containing loads will be placed on one of two infeed conveyors at the interface between the warehouse and the production area using a forklift. From this point, the loading units will be transported fully automatically through the conveyor system until they are placed on the appropriate shelf of the high-bay rack by one of the stacker cranes. During this process, the barcode on the load will be read and the load will be secured using an automatic hooding system (two such subsystems are planned).
Before being placed in the warehouse, pallets will be automatically inspected for weight, pallet quality, and load contours. Pallets with errors will be directed to the NIO ("Not In Order") station, where appropriate corrections will be made.
Pallets will be unloaded from the warehouse by stacker cranes and transported by conveyors to one of two shipping areas, where they will be consolidated into full loads for truck trailers (up to six vehicles) and buffered. In total, the automated Kardex Mlog high-bay warehouse will offer a maximum throughput of approximately 200 pallet movements per hour – approximately 100 pallets per hour for incoming and outgoing unit loads.
The Kardex Control Center's modular software solution, which includes the Kardex WMS warehouse management system and the Kardex MVisu plant visualization system, will optimize material flow in the high-bay warehouse. Kardex MVisu provides a graphical representation of all conveyors and stacker cranes, as well as their operating status. Item information will be managed in the customer's WMS system. Changes or additions will be automatically transmitted to the Kardex Control Center.
The project is complemented by Kardex Mlog's comprehensive Life Cycle Service. This comprehensive package, which includes maintenance, spare parts delivery, on-site service, and phone support, typically has an initial term of two years. Kardex Life Cycle Service supports logistics systems throughout their entire service life, ensuring maximum reliability and maintaining state-of-the-art technology. Customers can configure a personalized maintenance concept using six service modules.
In summary: With its first fully automated high-bay warehouse in Poland, modern plastic packaging manufacturer Jokey will fully utilize its current potential and ensure highly efficient processes with minimal manual intervention. This will allow the company to unlock valuable human potential, redirecting it toward higher‑impact, value‑added activities that drive innovation and enhance overall service quality.
Jokey, a family-owned company headquartered in Wipperfürth, Germany, is one of the world's leading manufacturers of injection-molded plastic packaging. The group develops and produces high-quality, recyclable packaging solutions for food and non-food applications, offering its customers industry-specific services related to packaging design, customization, and sustainable concepts. Its international production and service network, combined with modern, digitally supported processes, ensures efficient and resource-saving packaging solutions for a wide range of industries.
With approximately more than 2300 employees at 14 plants in 11 countries, with a total machine park of over 600 injection molding machines. Its product range includes buckets, cans and jars, rectangular and oval containers, and specialized packaging systems for the circular economy. Jokey has been committed to sustainable materials, high recycling rates, and energy-efficient production for many years, and is a pioneer in the field of eco-friendly plastic packaging.
Jokey Poland Sp. z o.o., where the investment is being carried out, has been operating in Kędzierzyn‑Koźle since 1995. It was Jokey’s second foreign branch, serving as one of the key production sites within the international Jokey Group. The Polish plant currently employs around 200 people and generates a turnover of over 55 mio EUR. In addition to polypropylene packaging, Jokey Poland was the first plant in the group to start a new phase at the end of 2024 – production using ISBM technology (Injection Stretch Blow Moulding) – thereby expanding its product range to include everything from small containers to large jars. A modern warehouse will be the perfect support for the next planned stages of the company's development. More information about Jokey can be found at jokey.com.
Kardex is a leading global partner for innovative intralogistics solutions, comprising four business divisions: Remstar, Mlog, AS Solutions, and ROCKETSOLUTION. Headquartered in Switzerland, the company operates production facilities in Germany and the USA. Kardex offers intelligent pathways to automation through dynamic storage and retrieval systems, integrated material flow systems, small-parts storage, and automated high-bay warehouses.
As a global AutoStore™ partner, Kardex also delivers scalable solutions for highly efficient order fulfillment. Its broad portfolio is complemented by comprehensive services throughout the systems' lifecycle, as well as modernization and expansion projects carried out during ongoing operations.
Kardex employs over 2,900 people in more than 30 countries and has been listed on the SIX Swiss Exchange as Kardex Holding AG since 1989.
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