Hexar Solutions

Case Study: Kardex Vertical Carousel Install for a Brisbane Logistics Operator

A Brisbane logistics operator running out of pick-face capacity asked us to wire and integrate a Kardex Vertical Carousel (VCA) — the kind of automated vertical storage you see in third-party logistics warehouses and parts distribution. The job ran four weeks, came in within budget, and the carousel was running production picks the Monday after commissioning.

Talk to us about your site · Call 1300 365 700 · [email protected]

The challenge

The site had a 1990s-era main switchboard with no spare three-phase ways. The VCA needs a dedicated 25A three-phase feed and a clean earth, and the customer wanted staff EV bays added in the same programme to make the most of the one outage window we could get from operations.

What we did

Three-phase 415V supply from the main switchboard to the VCA via a new sub-board.
Sub-board sized for the VCA plus four 22kW AC EV bays and 30% spare capacity.
Schneider EVlink Pro AC bays with EcoStruxure load management.
Machine wiring from sub-board to VCA, including emergency stop integration and safe isolation.
Commissioning with the Kardex integrator, including PLC sign-off and operator training.
Form 17 lodged, Energex application for the increased supply allocation, sub-board labelling and asset register update.

The outcome

Carousel commissioned on schedule. The operator added one shift’s worth of pick capacity without expanding the building footprint. EV bays were live the same week, so the company car fleet started charging on site instead of paying public-network rates. The customer has since asked us back for two further automation projects.

The stack

Kardex Vertical Carousel VCA (integrator-supplied)
Schneider Electric switchboard, Acti9 protection
Schneider EVlink Pro AC chargers
EcoStruxure EV Charging Expert (dynamic load management)
AS/NZS 3000:2018, AS 4024 (machine safety), AS/NZS 61851 (EV supply equipment)

What we’d tell another customer

If a customer is putting in automation hardware, ask about EV charging in the same conversation. Doing the switchboard work once saved this operator about $11,000 versus running it as two separate jobs six months apart.

Talk to us about a similar project

If you’re planning warehouse automation, an industrial workshop fit-out, an EV charging rollout, or a switchboard upgrade in Brisbane, we’d be happy to come and look at the site. Free assessment for commercial work. Call 1300 365 700 or request a site visit.