Wacker Chemie AG optimizes logistics efficiency with SCIO Automation

Wacker Chemie AG faced the challenge of expanding its production capacity for semiconductor-grade polysilicon. Driven by growing demand from the semiconductor industry, the company needed a fully automated end-to-end solution that combined purity, process reliability, and scalability. For the new cleaning line at the Burghausen site, the goal was to create a continuous material flow that met the industry’s requirements while sustainably increasing production output.

Pooling SCIO's Expertise

In the spring of 2022, SCIO Automation, acting as general contractor, secured the contract from the well-known chemical company. To ensure the successful implementation of the facility, several SCIO divisions pooled their expertise: Warehouse Intrasolutions took charge of project management, SCI contributed its expertise in cleanroom logistics, and the SCIO teams from Eching and Duisburg provided support with robotic solutions and technical documentation. 

The Technical Solution

After the contract was awarded in May 2022, the project team began the planning phase. Within a few months, it developed a digital layout of the entire facility, including a central high-bay warehouse for small load carriers (SLCs). This layout illustrated the complex structure of the facility:

It included conveyor systems for the fully automated transport of the KLTs to the various production steps, handling devices at the transfer points to the process equipment, as well as input and output stations for the manual loading and unloading of KLTs with or without contents. 

The facility included eight robotic cells as well as custom-designed stainless steel conveyor systems. This combination ensured the highest precision and cleanliness required for handling polysilicon.

The Project at a Glance

High-bay warehouse: 

• 5-digit number of storage locations for KLT containers

• 6 aisles (stacker cranes) 

• Double-depth storage 

• High-bay warehouse nearly 30 meters long, with double the height relative to the width

Conveyor technology: 

• Over 500 meters of container conveyor technology + process tray conveyor technology

• 8 robots (lid grippers, tray grippers, emptying grippers)

• 2 levels

• Supply to 5 interfaces 

• 5 fire doors (conveyor system closures) 

Experience as a Key Success Factor

Thanks to SCI’s previously successful “umbrella project,” in which over 50 running meters of cleanroom conveying technology were installed, the team was able to build up in-depth expertise regarding the specific requirements of Wacker Chemie AG. This knowledge helped to optimally leverage synergies within SCIO for this project as well. As a result, the entire system was implemented with a high degree of precision. At the same time, the complete conveying system—including both cleanroom conveying technology and specialized container conveying technology—was provided from a single source.

The efficient coordination within SCIO Automation led to further milestones, from the pre-assembly of the conveying system in Benningen through the Factory Acceptance Test in Osterhofen to the virtual commissioning in June 2023.

Virtual Validation: The Digital Twin

The digital twin played a central role in the project’s implementation. It made it possible to thoroughly test the interaction of all IT and plant components and to train operators at an early stage. This ensured proper functionality in advance and significantly accelerated the subsequent commissioning of the actual plant.

A first look at our project simulation:

Increased Capacity

Commissioning of the conveyor system in Burghausen began in March 2024. The fully automated system then underwent a test phase in September 2024 before going into operation in 2025. The result: The entire facility increased Wacker Chemie’s production capacity for high-quality semiconductor-grade polysilicon by more than 50 percent. 

Unique Challenges in Material Handling

The particular appeal of the project lay in the material properties of the individual components, as preventing product contamination is crucial. For example, the silicon requires separate surface cleaning because minor contamination with foreign atoms cannot be completely avoided when breaking the previously deposited silicon rods. For demanding semiconductor applications, the broken silicon is therefore etched with highly concentrated acid. This made the tests using material samples from Wacker particularly exciting.

Working Together to Achieve Optimal Results

Thanks to the successful collaboration between the various departments at SCIO Automation, led by Warehouse Intrasolutions, and a consistently close and constructive dialogue with Wacker Chemie AG, all requirements were met and a tailor-made solution was created for the chemical company. 

The result is a productivity increase of over 50 percent thanks to reliable system performance.

Visit SCIO Automation at Automate 2026

Experience this intralogistics project firsthand at Automate with a live demonstration using VR simulation at our SCIO booth!

 Immerse yourself directly in the automated logistics facility and experience how complex material flows, intelligent control systems, and virtual planning interact within an immersive environment.

We will also be offering expert consultations with our logistics specialists at Automate, as well as additional examples of how integrated automation can enhance resilience and competitiveness in modern production environments.

📍 Chicago (USA)

👥 SCIO Automation and Member CEC Controls

📅 June 22-25 | Booth 19023 | North Hall

SCIO Automation enables the future of intelligent factories – experience how live in Chicago this June.

Or contact our warehouse experts and see more intralogistics solutions in advance - here:

💡 SCIO Automation | Warehouse Intrasolutions