Kaufland’s logistics centre in Geisenfeld near Ingolstadt is now largely automated after a three-year expansion phase. The technology for the newly opened high-bay warehouse at the site was provided by Vanderlande, the Dutch specialist in process automation. The high-tech distribution centre serves as a model for the retailer’s other logistics locations. Some of the solutions were developed or adapted by the company specifically for the site.
In 2020, Kaufland had already made the decision to transform its Geisenfeld operation into an almost fully automated high-tech logistics hub. Schwarz Group’s superstore operator introduced the technologies for this successively in the various sections of the distribution center. With the innovative high-bay warehouse for the case level units, the retailer was able to increase its storage capacity without expanding floor space. The storage area now totals 120,000 square metres. With the help of robotics, up to 185,000 packages can be picked in the food area.
Depalletising is largely handled by robotics. After the case level units have been separated, storage and retrieval machines automatically move them into the innovative Adapto high-bay warehouse developed by Vanderlande and Kaufland. They remain there until the goods are needed. The 200 shuttle vehicles from Vanderlande take care of storage and retrieval in a way that saves the retail company a lot of conveyor technology for sorting the cases after retrieval. An innovative automation technology, which combines 12 robot gripper arms with pushers, then assembles the load carriers individually for the individual shops. The cases are arranged in the order that corresponds to the layout of the relevant stores.
Smart software controls transport of goods
The system wraps all load carriers fully automatically, including those that had to be loaded manually due to the nature of the goods. Autonomous transport vehicles then move two packed pallets each at a time to the shipping area in correct sequence. The so-called guided vehicles replace conventional forklift trucks. They use cameras and sensors to navigate and to avoid obstacles.
Vanderlande customised the solution for Kaufland. Konrad Ott, Project Manager Automation at Geisenfeld, told Lebensmittel Zeitung that the vehicles in its standard version were too slow and required too much manoeuvring space. The technology provider was able to solve the problem applying software made for luggage transport vehicles at airports.
BSS Bohnenberg automates fruit and vegetable picking
The order picking system for fruit and vegetables was also customised. Kaufland designed it together with technology provider BSS Bohnenberg. The Schwarz Group’s superstore operator is already using it at its logistics locations in Dortmund, Möckmühl, Lübbenau and Osterfeld. The automated picking system can put together up to 50,000 packages per day and process different combinations of various transport boxes. Kaufland won an Reta Award from the EHI Retail Institute for this project this year.
In an interview with Lebensmittel Zeitung, Konrad Ott stated that 60 per cent of the entire distribution centre is currently picked automatically. Employees are responsible for separating products that are not suitable for automation. The company is in contact with suppliers to adjust packaging if possible.
