Flexibility is the Special Ingredient for Food and Beverage Automation

Food & Beverage

Warehouse automation systems for the food and beverage industry are often characterized by handling large volumes of pallets in highly dense distribution centers or in high bay warehouses. But today, the variety of articles is increasingly moving towards smaller quantities for flavor and variety, so automated systems for case picking and storage are also becoming popular. The requirements of end-user customers are becoming more distinctively different, and as a result, so are the demands on intralogistics. Seasonal products are subject to high volume with limited shelf availability. This places special demands on system scalability and the performance of system components as well, like conveyor technology and warehouse management software. Furthermore, tracking down to the lot level and implementing a complete turnkey solution that slots products and retrieves based on expiration dates, plus store in temperature-controlled zones is second nature to the food and beverage industry. This is where the expertise from GEBHARDT helps food and beverage clients. GEBHARDT engineers, implements, and services various food and beverage automation systems to optimize costs and efficiency.

High-bay Pallet Warehouse for Highly Dense Storage

An automated high-bay warehouse maximizes the use of available space for pallet storage. Automation also makes it possible for a highly dense warehouse operation while lowering energy costs--something that is crucial in cold chain environments. Large, automated pallet cranes easily store and retrieve pallets. Both pallet and case picking can also be automated. Robotic palletization and depalletization help boost throughput and offset labor costs, while protecting employers from potential injuries.

For Ostfriesische Tee Gesellschaft's (OTG) Lager- and Frachtkontor Süd (OLF Süd facility, GEBHARDT established an updated highly dense pallet high bay warehouse distribution center for OTG in Grettstadt Bavaria. The video here is in German, but you can still see the operations. If you would like to find out more, click the, "read more here" button or feel free to reach out to GEBHARDT to request more information.

Real-time Monitoring of Logistical Processes Enables Maximum Transparency

Real-time monitoring of workflow processes enables maximum transparency and documentation for the food and beverage industry. Unfortunately, food recalls are part of the industry, and GEBHARDT warehouse management software creates this process transparency by using the latest in software technology in conjunction with warehouse automation. By integrating GEBHARDT StoreWare®, processes are automatically traced for regulatory purposes. Furthermore, scan data capture technology ensures that lot and expiration dates are not only captured but recorded. This enables regulatory requirements such as batch tracking. Plus, automation increases order picking accuracy, which saves cost on wrong orders. GEBHARDT also makes it possible to handle omnichannel fulfillment too. So, if you have a direct-to-consumer model, GEBHARDT can ensure that you meet the needs of both end-user customers along with retail and wholesale, and any food service providers. Plus, GEBHARDT handles route sequencing and zone loading so food can stay fresh all the way to delivery.

GEBHARDT sortation system used to target wine and restaurant delivery routes for beverage cases.

Customer-Oriented Order Picking

When supplying end customers, high delivery frequency, error-free order picking of large article varieties and the ability to handle a wide range of SKU containers and case units are crucial. Depending on the degree of automation, different order picking systems such as Pick by Light are often utilized. Paperless order picking leads to enormous efficiency gains.

Here, you see a beverage wholesaler who supplies wine and spirits to restaurants and bars from its distribution center. Several pick tunnels, each with eight order picking workstations and in use. In this application, a sorter is utilized in the the outgoing goods department to target various delivery routs and destinations.

Automated Intralogistics as an Enabler for the Digitalization of Food Production and Distribution

Automated storage and order picking systems enable high delivery performance and an optimum utilization of space. The individual process steps inside a warehouse must be linked together with appropriate material flow technologies. Multi-deep automated warehousing and digital order picking systems make it possible to achieve high density storage. Food and beverage manufacturers are in a competitive environment with high price pressure. Automated systems enable a competitive edge where these organizations can compete.

A Multi-Deep Automated Pallet Storage Solution for a High-Density Distribution Operation

Multi-deep storage systems offer a high degree of flexibility because these warehouses can and are often organized based on the last-in-first-out (LIFO) storage methodology as well as on the first-in-first-out (FIFO) basis—and can include expiration and / or lot / batch numbers. This warehousing structure is the ideal solution in terms of space-saving storage for a large number of pallets. The system shows its advantages when full and when each warehouse channel is filled purely according to type.

Bosch Tienahrung, a pet food manufacturer, produces approximately 80 different in-house product SKUs, which are exported to over 35 countries worldwide. This family-run company from Europe not only places an emphasis on the high quality on its products, but also attaches great importance to customer-oriented service and a high-level of delivery readiness. To see the operation in action, click on the video link.

Ergonomic Work Environments Achieved through Automation

For employees, automation offers the chance of a workplace that prioritizes ergonomic design and functional safety. Companies that embrace automation reduce absenteeism and address the challenges of an ageing population, and both labor and skills shortages. Workplace ergonomics have a direct impact on the work results of their employees due to the high-performance requirements. Overall, automation reduces the proportion of manual work in the warehouse--making it easier to employ and retain employees.

Automation Promotes Sustainability

With automation, you are also investing in sustainability and resource conservation while at the same time meeting high requirements for economic efficiency. Plus, automation brings digitalization as an investment in information security. Automation of logistics leads to a reduction in labor costs over many years of plan operations and enables high efficiency even in countries with high unit labor cost. In addition, consumers are actively demanding goods from a sustainable supply chain. Our plants integrate modern IoT and industry 4.0 technologies. The ability to support many different storage and retrieval methodologies cuts down on food waste. Furthermore, our cold chain facilities are built to help keep energy conservation at the forefront.