A day at Hetzner Online in the Falkenstein Data Center: insights into server technology, cooling, production, RMA and sustainability

My visit to Hetzner Online in Falkenstein goes far beyond a tour of a server, as the site reveals an impressive combination of industrial precision, technical depth and a logically sophisticated infrastructure. As soon as you enter the expansive grounds, it becomes clear that this is a data center park that has evolved over many years and is now one of the most extensive sites of its kind in Germany. The pathways between different areas are long and winding, the buildings are spread over a large area and even the internal transport routes look like the access roads of a small industrial area. Anyone planning a similar project should really be prepared to walk many kilometers and prefer sturdy shoes, as workers in this environment also cover considerable distances every day. And because I know you’d love to see someone else sweat in the heat, I made a movie of this experience today:

And if you want to read about what you saw, here’s a recap of today’s action:

The highly structured layout of the site is already evident at the main entrance. After registration, the tour progresses directly to the colocation area, where customers can operate their own hardware and access a full-fledged data center environment. The modular arrangement of the racks, the clearly separated supply routes and the functional design present an image of the precise organization that was to prevail throughout the journey.

From there, we moved on to MIDI data centers, which are designed as compact modules and still meet all the requirements of a modern data center. This part of the park clearly demonstrates Hetzner’s focus on practicality, as there is nothing unnecessary here. Everything is designed for smooth processes, low maintenance time and high energy efficiency. The simplicity on the outside is deceptive, because the infrastructure inside largely meets the requirements of a large-scale IT operation in every respect.

This route then took me to areas where actual domestic production is visible. Hetzner produces a significant portion of its servers itself and relies not on exaggerated presentation, but on robust construction and standardized processes. Individual components are tested first, followed by assembly of the system with clearly defined work steps before the equipment is transferred to the broader test track. Test benches for hard disks and SSDs run continuously to ensure reliability and long-term stability. In addition, there are areas for hardware service, RMA processing and full testing of 19-inch systems, so that faulty components or components requiring replacement can be processed directly on site.

Another station was the production and processing of rack and open frame systems, which are used for cloud services, object storage and internal production environments. This section shows particularly clearly that Hetzner deliberately relied on functional design and regional suppliers. The racks are finalized, tested, and prepared for continuous use in an in-house data center environment. Airflow, stability and ease of assembly are the main focuses, as every second and every move counts in large-scale deployments.

Finally, in the decommissioning area, it becomes clear how carefully the entire life cycle of the hardware is handled. Discarded devices undergo a complete documentation process before being destroyed in a specially certified shredder, rendering both magnetic hard drives and SSDs safely and permanently unusable. The remains then enter the regulated disposal process, which is also documented in detail.

The technical foundation of the site is particularly noteworthy. The frequent use of redundant power supplies, sophisticated network connections and free cooling creates a system that enables maximum operating comfort with the lowest possible energy consumption. Thanks to the climatic location in the Vogtland region, a large part of the cooling can be achieved using outside air alone, resulting in low PUE values ​​and a very stable thermal environment. The technical impact is so impressive that you almost forget how much work goes behind the implementation and ongoing operations.

Tourists soon realize that visiting Falkenstein is by no means a short detour. The dimensions, number of halls and distribution of individual production and service areas inevitably mean that many kilometers have to be covered on foot. So good running shoes are not a bad recommendation. Anyone interested in infrastructure, technology and data center processes will gain a deep insight that goes far beyond what you would expect from the outside. Falkenstein is not an anonymous data space, but a highly organized interplay of production, service, operations and security that is rarely seen in this form. If you can come in…

So much for the script, but for now just watch the finished cinematic product, because the videos don’t hurt and I kept it really short!

And if anyone is still looking for a good deal: Click here! (No affiliates, just a small thank you to the tour guides)



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