Rolf Benz produces luxurious sofas, armchairs, tables, chairs, and home accessories "Made in Germany".

IGZ Automation has already upgraded two of the company's automated plant systems.

These projects involved bringing a twin-aisle automated small parts storage system from PSB and a Schöneberger Power-&-Free system up-to-date.

Formed in 1964, Rolf Benz AG & Co. KG is a manufacturer of premium-quality, exclusive upholstered furniture "Made in Germany". Rolf Benz has been a Hüls Group company since 1998. Members of this group include other familiar furniture industry brands such as hülsta, Parador und Ruf|Betten. Rolf Benz produces its furniture exclusively at its Nagold and Mötzingen sites in Baden-Württemberg. Today, this prestigious international label stands for first-class design, a passion for style and uncompromising comfort.

At its Mötzingen site, Rolf Benz AG & Co. KG needed to upgrade its automated small parts storage and conveyor system in the production area adjoining its sewing workshop. This system consists of twin stacker cranes and conveyor plant from PSB.

The main reason for this retrofit was the dependency on specialised "custom components" and the associated lack of a steady supply of spare parts. The objective was to stabilise and improve overall system operations.

Rolf Benz also operates a Power-&-Free lane for hanging items as a buffer lane near the sewing workshop. The existing control technology had since become outdated and needed to be modernised. The transportation system uses bags on hanger carriers. Another key aspect was the harmonisation of interfaces from the production control system to the plant systems.

AS/RS for small parts

  • Upgrade plan
  • Integration of new scanners
  • Stacker crane replacement (physical + control system)
  • Replacement of conveyor system switch gear
  • New interface to the production control system

Power-&-Free system

  • Upgrade plan
  • Integration of new scanners
  • Replacement of 2 Siemens S5 control units with S7

  • High level of system transparency
  • Stable operation
  • Increase in overall availability
  • Greater flexibility within processes
  • End-to-end documentation
  • Efficient modernisation without production downtime
Key Facts


Automated small parts storage:

  • Installation of 1x stacker crane to replace 2x existing cranes for small parts storage
  • Modernisation of conveyor system for AS/RS (for small parts)
  • 7 scanners
  • 26 sewing workplaces
  • 2 Siemens PLCs (S7)

Power-&-Free plant:

  • Modernisation of Power-&-Free conveyor system
  • 13 scanners
  • 9 sorting loops
  • 1 Siemens PLC (S7)

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