Future-proofing material logistics in heavy steel industry with the STOPA LG-E shelving system

In heavy industries like mining, construction, and industrial manufacturing across Australia and New Zealand, operational efficiency and space optimisation are critical to maintaining productivity and competitive advantage. With increasing global demand for high-performance equipment, manufacturers must continuously invest in smart warehousing solutions that enhance material handling, storage efficiency, and automated inventory management.

One company leading this change is Lehnhoff Hartstahl. With a reputation for excellence in material handling machinery and excavator attachments, Lehnhoff sought to modernise its material storage and retrieval operations to meet evolving customer expectations and future growth. Investing in STOPA’s LG-E shelving system for long-span goods—a system designed to optimise space, protect materials, and enable automated, accurate inventory management.

About Lehnhoff Hartstahl: Lehnhoff Hartstahl GmbH & Co KG is a leading safety system innovator within the construction and excavation industries. Renowned for its robust engineering and operator-focused design, Lehnhoff develops advanced systems that enhance safety and operational control for heavy machinery—particularly excavators used in high-risk environments like mining, civil construction, and infrastructure projects. More about Lehnhof

Challenge: Inefficient storage & logistical bottlenecks

Lehnhoff’s rapid expansion and growing production demands brought logistical bottlenecks, particularly in storing and retrieving long-span goods like steel profiles, beams, and large-scale raw materials. Their existing horizontal storage method consumed excessive floor space and limited visibility into inventory. This created production delays, increased risk of material damage, and made stocktaking labour-intensive.

To stay competitive in the mining and construction equipment sector, where delivery timelines are tight and materials are bulky and costly, Lehnhoff needed an advanced, automated solution to streamline storage operations, safeguard materials, and support lean manufacturing practices.

Solution

Lehnhoff implemented the STOPA LG-E shelving system for long-span goods, a high-density vertical storage solution engineered for heavy-duty industrial environments to address these challenges. This decision aligned with the company’s strategic move toward Industry 4.0 and smart manufacturing technologies.

Key benefits of the STOPA LG-E system include:

• Maximised storage efficiency: Vertical shelving significantly reduces required floor space compared to conventional horizontal methods.
• Faster access & retrieval: Materials are stored in structured, dedicated cassettes that enable rapid, automated access—minimising downtime and improving workflow.
• Material protection: Each cassette isolates goods to reduce physical contact and risk of damage, crucial for high-cost steel components and precision parts.
• Real-time inventory visibility: Integrated software enables accurate stock monitoring, automatic stocktaking, and synchronisation with ERP systems.
• Customisable layout: The system’s modular design allows for tailored configuration of storage/retrieval stations, fitting seamlessly into Lehnhoff’s manufacturing environment.

Implementation

Lehnhoff’s implementation of the STOPA LG-E system was managed in partnership with STOPA’s technical team, ensuring alignment with production schedules and minimal operational disruption.

The process involved:

• Assessment and planning: Material dimensions, weight capacities, and site layout analysis to define cassette requirements and retrieval workflows.
• System installation: Deployment of the vertical racking infrastructure and integration of STOPA’s proprietary warehouse management software.
• Operational integration: Connection to Lehnhoff’s internal systems to facilitate seamless data flow, improve traceability, and enable automated replenishment.
• Staff training: A comprehensive training program ensured smooth system adoption by warehouse and production staff, maximising ROI from day one.

Within the first few months, Lehnhoff saw measurable gains in speed, safety, and material control. Retrieval times were cut significantly, while the risk of material misplacement and handling damage dropped sharply. The storage system not only delivered on immediate logistical needs but also positioned the company for scalable, long-term growth.

By connecting the LG-E system directly to CNC machines and laser cutters, Lehnhoff achieved a seamless material flow, boosting productivity and supply chain efficiency.

Mr. Spengler, Engineering Manager at Lehnhoff says:

“We’re highly satisfied with the solution we’ve chosen, which was based on a longstanding relationship with a partner in our vicinity. Our first order from STOPA was for a sheet metal storage system, and now we’ve invested in our first shelving system for long-span goods. We estimate that it will pay for itself in two years.”

Conclusion

In the mining and construction manufacturing space, where downtime is costly and precision is critical, Lehnhoff Hartstahl’s investment in the STOPA LG-E Shelving System has proven a strategic leap forward. By combining efficient use of space, automation, and real-time inventory management, the system delivers a future-ready solution that supports high-volume, high-performance operations.

Ready to optimise your operations, scale locally, and compete globally?

Contact our STOPA experts to discover how high-density shelving systems can future-proof your facility, boost productivity, and streamline operations in Australia and New Zealand.