Crown solutions ensure efficient warehouse processes at PACCAR Parts
Smooth picking processes in the warehouse are a top priority for PACCAR Parts. The spare parts supplier relies on Crown, one of the world’s largest material handling solutions companies, for support.
With brands such as DAF, Kenworth and Peterbilt, PACCAR Inc. is one of the world's largest commercial truck manufacturers. The group's subsidiary PACCAR Parts is responsible for global spare parts supply and operates 20 distribution centres on four continents. One of its core markets is Germany, where PACCAR Parts opened a state-of-the-art warehouse in Maßbach, Bavaria, at the end of 2024. Located on a 22-hectare site, the Parts Distribution Centre (PDC) supplies spare parts to DAF dealers and customers in Germany, Switzerland and eastern France. With an area of 22,500 square metres and around 15,000 pallet spaces, the PDC offers space for over 80,000 spare parts of various sizes and types. As in all its warehouses, PACCAR Parts also relies on a high-performance fleet solution from Crown for storage and retrieval in Maßbach.
Efficient order picking for time-critical orders
The PDC was designed for the rapid processing of high order volumes, which is currently supported by approximately two dozen employees. Working in two shifts, they handle over 2,000 order lines per day and are well prepared to fulfil time-critical orders. Thanks to the efficient concept, orders received at the warehouse by 8 p.m. are shipped the same night to arrive at the customer's premises the next morning.
The fast processes required for this are significantly supported by the fleet of 29 Crown forklifts. This ensures time-saving and efficient handling of storage and retrieval. PDC manager Kai Rohden can confirm this: “The Crown products are perfectly tailored to our workflows. They also meet the high demands we place on our trucks.”
Three Crown SC Series electric counterbalance forklifts are used at the beginning and end of the material flow in the warehouse. In addition, there is a C-B Series counterbalance forklift, which is designed for the fast picking of particularly demanding loads. Among other things, the four forklift trucks are responsible for loading and unloading and transporting pallets and heavy parts in the PDC. Their robust construction ensures outstanding reliability and load capacity in daily use.
Efficient handling in high-bay warehouses
PACCAR Parts relies on ESR Series reach trucks specifically for pallet handling in its high-bay warehouse. Eight of these reach trucks have been in use since the PDC opened, contributing to effective staging processes. Thanks to their manoeuvrability and precise control, the reach trucks can also demonstrate their performance ideally in the limited space of the narrow aisles of the warehouse. With their fast lift and lower speeds, they support fast order picking, especially at greater heights, with the process being further accelerated by Crown's Xpress Lower technology.
Another key contributor to high performance is the use of nine SP Series man-up order pickers. Designed for dynamic, high-density environments, they help busy operators efficiently handle a wide range of tasks. OnTrac traction control enables safe manoeuvring in narrow aisles, while excellent all-round visibility allows operators in the high-bay warehouse to precisely target pick locations at heights of over 11 metres.
At PACCAR Parts, spare parts are stored not only in high-bay warehouses, but also at low and medium heights. To optimise picking operations in these areas, the company uses six Crown WF Series stackers. These ensure fast transport of bulky and heavy loads. The intuitive operation of these stackers also makes daily work much easier, as PDC manager Kai Rohden confirms: “Our employees are convinced of the quality and user-friendliness of the trucks. They offer comfortable handling and ergonomic workstations, coupled with high reliability.”
Two GPC Series order pickers are also used specifically for working with low-level pallets.
High energy efficiency and reliability thanks to V-Force technology and InfoLink
When it comes to ensuring a reliable energy supply for the fleet solution, the two project parties make no compromises. This is achieved through Crown’s V-Force technology, which combines lithium-ion batteries with a high-performance charging infrastructure to deliver excellent energy efficiency.
The solution is characterised by reliability and fast charging times: flexible opportunity charging ensures that there is always enough energy available, even in a demanding two-shift operation, making time-consuming battery changes obsolete. At PACCAR Parts, operators charge the forklifts during their breaks in a specially designated area. The permanently installed V-HFB chargers with charging currents of up to 200 A ensure that the batteries are supplied with sufficient energy even after short breaks.
In addition, the Crown InfoLink operator and fleet management system used in Maßbach meets PACCAR Parts' requirement for high reliability. According to InfoLink specifications, each lift truck is thoroughly inspected at the start of each shift and various checks are performed to confirm that it is in proper working order. At the same time, the control software assigns usage authorisations. For example, experienced employees can operate the forklifts at higher lifting speeds than operators who are less familiar with the respective systems.
Long-term high performance thanks to Crown's consulting concept
PACCAR Parts is another example of how the success of a project depends on more than just the hardware and software used. Decades of expertise and consulting services provided by the Crown service team laid the foundation for the design of fleet solutions and efficient logistics flows at the PDC in Maßbach. Even after the project's completion, two Crown service technicians remain available to PACCAR Parts, ensuring Crown’s brand promise: when every minute matters, customers can count on Crown to keep their businesses moving.
About PACCAR Parts
PACCAR Parts is a subsidiary of PACCAR Inc. from the USA. The manufacturer of DAF, Kenworth and Peterbilt trucks is one of the largest commercial vehicle manufacturers in the world. PACCAR Parts is responsible for supplying spare parts for the vehicles and operates 20 logistics centres in North and South America, Australia and Europe.
In addition to effective processes and high safety standards, sustainability played a major role in the design of the warehouse in Maßbach. Around 4,000 solar modules mounted on the roof ensure that the PDC covers 97 percent of its energy requirements over the course of the year and also has sufficient capacity to refuel electric trucks.
About Crown Equipment Corporation – EMEA
Crown is one of the world’s largest material handling companies with a reputation for award-winning product design, advanced engineering and technology, as well as superior after-sales service. For 80 years, Crown’s business philosophy utilises vertically integrated processes to design, manufacture and distribute forward-thinking, innovative solutions that improve customers’ productivity and operating efficiency. Crown produces a broad range of forklifts, batteries and chargers as well as automation and fleet management technologies.
The company’s global headquarters is located in New Bremen, Ohio, USA, with regional headquarters in Germany, Australia, China and Singapore. Its employees number 20,900 worldwide. Crown operates a service and distribution network that exceeds 500 retail locations in over 80 countries. To learn more about Crown’s ideas for helping customers advance the productivity of their operations, visit crown.com.