Driving innovation and operational excellence with Hanel automated storage and smart intralogistics systems

SEW-EURODRIVE, a leader in drive technology and modular motion systems, faced a growing challenge, expanding inventory and limited storage space that threatened efficiency and order fulfilment. To address this, SEW-EURODRIVE partnered with Headland Technology to implement Hanel’s cutting-edge automated storage and retrieval system (ASRS). The result: a cleaner, safer, and smarter warehouse with significantly improved efficiency, accuracy, and throughput.

About SEW-EURODRIVE: Founded in Australia in 1982, SEW-EURODRIVE is part of a global powerhouse in drive technology and automation solutions. With over 320 employees nationwide, including 180 team members at its Melbourne headquarters, SEW-EURODRIVE delivers custom drive systems across diverse sectors, including mining, food and beverage, manufacturing, and logistics.

The company operates as part of a global network of 17 production plants and 92 Drive Technology Centres, providing local engineering expertise backed by international R&D. SEW-EURODRIVE maintains a strong commitment to quality, innovation, and collaboration, all underpinned by ISO-certified manufacturing and a customer-centric approach. More about SEW- EURODRIVE

The challenge

With sustained growth and a constantly expanding product range, SEW-EURODRIVE faced an increasingly complex warehouse environment. The company needed to:

• Optimise limited warehouse space while accommodating larger inventory volumes.
• Improve process flow and safety for staff operating within a busy environment.
• Integrate seamlessly with their SAP ERP system to manage real-time inventory.
• Eliminate bottlenecks and reduce picking errors while handling diverse items from small fasteners to sensitive electronics.
• Implement a flexible, scalable, and open-source solution without the need for expensive third-party licenses.

As National Procurement Manager Fred Pizzicara explained, SEW required an intralogistics solution that balanced technical sophistication with ease of operation, ensuring the warehouse could keep pace with growing customer demand and tighter lead times.

The solution: Hanel Lean-Lift technology

After evaluating SEW-EURODRIVE’s operational challenges, Headland Technology recommended the Hanel Lean-Lift, a vertical lift module (VLM) engineered for precision, flexibility, and integration.

Manufactured in Germany, the Hanel Lean-Lift is an automated vertical storage and retrieval system that utilises the full height of a facility to store goods efficiently while maintaining quick access and security. Each Lean-Lift consists of:

• Computer-controlled lift systems for fast retrieval and storage.
• Dust-protected, enclosed design ensuring parts remain clean and damage-free.
• Modular trays with weight-optimised shelves, allowing safe storage of both heavy and delicate items.
• Direct SAP integration enabling seamless data flow and live inventory tracking.

The Hanel Lean-Lift transformed SEW-EURODRIVE’s traditional warehouse setup into a vertically optimised, digitalised storage hub, dramatically improving space utilisation and operational control.

Headland’s implementation and support

We managed the full implementation, from consultation and design to installation, integration, and training. Leveraging their OEM-certified Hanel engineers, Headland installed the first Lean-Lifts within just one month, ensuring minimal disruption to daily operations.

The project team worked closely with SEW’s IT and operations departments, aligning system parameters with SAP for real-time stock visibility and automated transaction logging, all without the need for middleware or additional software licensing.

Training was delivered onsite, enabling rapid staff adoption. As Paul, Senior Storeperson at SEW, noted, it took him just half a day to learn and operate the system confidently. Controlled user access ensured data integrity while allowing authorised users to retrieve parts efficiently.

Fred Pizzicara praised the collaboration, highlighting that Headland’s expertise and approachable team were key to the project’s success:

“Headland’s experience and professionalism made all the difference. Their people are great to deal with, and their technical understanding ensured everything integrated perfectly with our systems.”

Outcomes and measurable impact

Since integrating the Hanel Lean-Lift systems, SEW-EURODRIVE has achieved remarkable improvements in operational performance:

• 80% reduction in warehouse footprint, thanks to vertical space utilisation.
• Fivefold increase in overall warehouse efficiency, enabling faster order fulfilment.
• Near-zero picking errors, achieved through automated item retrieval and SAP integration.
• Enhanced safety and cleanliness, with goods stored in enclosed, dust-free environments.
• Significant labour cost reduction, freeing skilled staff for higher-value tasks.
• Real-time inventory accuracy, eliminating manual counting and data entry.

SEW-EURODRIVE now operates 14 Hanel Lean-Lifts at its Tullamarine facility, with plans to expand as customer demand grows. The modularity of the Hanel systems allows SEW to scale effortlessly as business needs evolve.

“The integration of Hanel with our SAP system has been seamless. We’ve reduced errors, improved speed, and gained more control over inventory; all without third-party software or additional costs.” – Fred Pizzicara, National Procurement Manager, SEW-EURODRIVE

Innovation spotlight: Enabling faster product development

Beyond operational efficiency, SEW-EURODRIVE’s investment in Hanel automation has directly contributed to faster product development cycles. With improved access to parts and real-time visibility, engineering teams can now prototype and deliver new drive solutions more rapidly, reducing time-to-market for innovative products tailored to Australian industry demands.

The smart integration of Hanel’s automated storage has allowed SEW to maintain just-in-time manufacturing, ensuring critical components are available precisely when needed; an essential advantage in today’s fast-moving industrial environment.

Advice to industry peers

When asked what advice he would give to other manufacturers considering automated storage, Fred was clear:

“Invest in automation early. If you want scalability, accuracy, and efficiency, Hanel systems deliver. And working with an experienced partner like Headland makes the process seamless.”

Conclusion

By adopting Hanel’s advanced Lean-Lift systems, SEW-EURODRIVE has set a new benchmark for intelligent warehouse management in Australia. The collaboration with Headland Technology has enabled SEW to reduce costs, increase space efficiency, and accelerate innovation, positioning them for sustained growth and customer responsiveness.

As demand for rapid, accurate order fulfilment continues to rise, SEW-EURODRIVE’s automated storage infrastructure ensures it remains at the forefront of industrial logistics excellence.

Are you ready to future-proof your warehouse operations?

Partner with Headland Technology, Australia’s and New Zealand’s leading expert in Hanel automated storage and retrieval systems and unlock the potential of smart intralogistics.

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