Retrofit at Aspen Bad Oldesloe – A modernisation Project that sets New Standards

How do you modernise a complex intralogistics system when operations, supply, and distribution must be ensured every single day?

Aspen Bad Oldesloe proves: Even under the demanding conditions of pharmaceutical production, a retrofit is possible during live operations, without disruption, and with long-term impact.

A Global Pharma Site with High Standards

Aspen is one of the world’s leading pharmaceutical companies, headquartered in South Africa and operating across six continents. The northern German site in Bad Oldesloe supplies patients in more than 150 countries with high-quality pharmaceuticals

500 employees ensure that production, storage, and shipping run smoothly. Intralogistics plays a key role in this: it not only coordinates internal material flows but also functions as a hub for active ingredients sourced internationally and for shipping to distribution partners worldwide.

With around 13.000 pallet movements per month, a powerful and highly available intralogistics system is indispensable.

Already during the first kick-off meeting, we realised that the chemistry between us and AM was right. The colleagues from AM approached the topic in a very authentic and professional way – that gave us a good feeling.

– Maximilian Schug, Head of Engineering, Aspen Bad Oldesloe

The Challenge: Retrofit in a Grown System Landscape

The intralogistics setup at Bad Oldesloe has evolved over decades shaped by building expansions, parallel system generations, and multiple structural transitions. It comprises three high-bay warehouses across several buildings and levels, complemented by an extensive conveyor system, automated robot cells, special machinery, and diverse generations of control technologies.

Despite reliable processes, many technical components were no longer future-ready.
A detailed system audit revealed clear action areas especially in three critical domains essential for operational stability, control, and integration:

• System availability: Outdated components increased the risk of unplanned downtime.
• Control reliability: Inconsistent standards complicated maintenance and diagnostics.
• Digital connectivity: The planned SAP EWM integration required a modern interface architecture.

A full system shutdown was not an option. The clear goal: a comprehensive infrastructure upgrade without interrupting operations.

The biggest challenge for us was maintaining production supply. With AM, we were able to coordinate exactly which parts of the system were affected and when, enabling us to ensure material availability.
— Jonas Müller, Shift Coordinator Warehouse, Aspen Bad Oldesloe

The Solution: Phased Retrofit – Targeted and Coordinated

In close collaboration with AM Logistic Solutions, Aspen chose a strategic retrofit approach. Rather than opting for a full rebuild, the modernisation was executed in stages carefully synchronised with operational workflows and ongoing production.

Core measures included:

• Consolidating the three high-bay warehouses into a unified system environment
• Upgrading control and drive technology to current industrial standards
• Implementing a modern communication architecture based on Profinet and TCP/IP
• Introducing a centralized visualization system using Siemens WinCC, enabling full transparency and control across all warehouse and conveyor operations

Project Scope

• 3 high-bay warehouses across multiple buildings and levels
• 10 stacker cranes (Warehouses 2 & 3)
• 3 aisle-changing stacker cranes (Warehouse 1)
• 4 conveyor zones with a total length of approx. 650 meters
• 4 transverse shuttles
• Integration of robot cells and third-party systems
• Centralized visualization of all warehouse and production areas
• Two-stage IT integration:
  • Connection to the existing warehouse management system
  • Step-by-step migration to SAP EWM, including comprehensive interface testing

The Result: Future-Ready, Fully Operational

Aspen Bad Oldesloe now operates a standardised, scalable, and high-availability intralogistics system. Thanks to modern communication protocols, interface complexity was significantly reduced, maintenance efforts lowered, and the foundation for SAP EWM integration established.

Key insight: Those who modernize strategically instead of rebuilding entirely gain twice — in cost-efficiency and long-term resilience. In the pharmaceutical sector, where downtime is not an option, that’s a decisive competitive advantage.

Retrofit as a Strategic Decision

A retrofit is more than a technical upgrade it is a forward-looking investment that redefines operational reliability, efficiency, and digital integration.

Aspen Pharma made this decision consciously maintaining full system availability, product quality, and operational performance throughout the process. The modernisation was executed during live operations and integrated seamlessly into existing workflows.

Key insight: Those who modernise strategically instead of rebuilding entirely gain twice in cost-efficiency and long-term resilience. In the pharmaceutical sector, where downtime is not an option, that’s a decisive competitive advantage.

Why Aspen chose AM Logistic Solutions:

Because we deliver more than technology we build sustainable strategies. Even in the most demanding environments.