As demand at Norbert Dentressangle’s hub in the Belgian town of Zellik has grown, the decision was taken to look for a modern logistics solution that could expand with their frozen food distribution business. The business itself is a fascinating set-up where goods ownership is transferred in a virtual transaction within the high bay warehouse.
The challenge for Swisslog was to deliver a complete deep freeze solution that could accommodate this efficient operation, within a live environment, on time and with minimum disruption.
Delivering in the Deep Freeze
Swisslog worked in collaboration with Norbert Dentressangle to consider all the opportunities and challenges facing a new installation. As one of the few companies able to offer a full turn-key solution including the building, Swisslog was able to not only oversee the construction of a new facility, but also develop the existing infrastructure and connect the two.
The process begins when palletised products arrive in a cool temperature controlled area from manufacturers. After being checked and scanned, the pallets are slaved where required and a special push unit straightens out any insecure loads.
Conveyors then lead the pallets to the highbay for storage at deep freeze conditions. Increased storage in the highbay was achieved through a variety of initiatives, including six Vectura standard deep-freeze cranes capable of storing pallets double deep within the harsh conditions, as cold as minus 280C.
Working in such temperature conditions presents a number of challenges – cables and steel are likely to shrink, plastic becomes brittle and fragile, many oils freeze and standard pallet cranes are simply unable to cope with the conditions. Swisslog’s Vectura cranes are equipped with freeze-resistant materials to deal with the environment. Special motors and drives are fitted, high grade oils are added to gearboxes, whilst heated cabinets offer protection to vulnerable parts. Other elements of the installation, such as steel structures that are subjected to stress, are impact strength tested for minus 30 degrees Celsius, and other plastic parts are adapted specifically for cold resistance.
Temperature is obviously a crucial issue, and a host of measures are taken to not only ensure that key components are insulated or heated if needed, but also that excess heat is not created to compromise the integrity of the installation. Further economies are made as the solution even re-uses the energy cooling the chilled environment to heat nearby offices. Once stored, products are picked for dispatch via VoicePick, a voice-operated retrieval system. Picked pallets are then brought to ground level before being shrink wrapped and transported to a special staging zone prior to being dispatched onto trucks. The whole process is completed in a matter of minutes, keeping products at maximum integrity and the warehouse at optimum efficiency.
A high tech fire protection system adds another layer of reassurance, eliminating the need for sprinklers.
Built for Growth
Energy conscious and efficient, the site is built for growth, easily capable of simultaneously moving over 130 pallets in and out.
Delivered in two phases, on time and within budget, the whole project has delivered more storage space whilst reducing operational costs. Having improved the efficiency of the reception of goods and delivered on the expected level of productivity, the installation has also had the added benefit of motivating those working within it.
Aside from the confidence engendered from having a single source supplier, designing, constructing and overseeing the project at all levels, Norbert Dentressangle has been able to develop the combined brown and green field site with minimal disruption. A new facility, with the potential for further expansion, now sits neatly alongside the existing, enhanced, operation. With the successful collaboration of both parties, the future looks bright for the start of a long term and productive relationship.
Interview WITH Koen De Smet Site manager, Norbert Dentressangle:
What prompted the search for a new solution and what were your main goals with this distribution centre?
We required an extention as a result of increased volume at our facility in Zellik. First and foremost, it was vital for the new solution to be fully aligned to our customers‘ requirements. At Norbert Dentressangle we invest in our customers, by enabling their supply chains to benefit from our operational performance. We work with customers to develop flexible, efficient and durable logistics solutions, so a contemporary materials handling solution was essential. As such, automation was the natural choice.
What made you choose Swisslog as your supplier?
Swisslog was selected from a list of potential suppliers, thanks to its experience, quality and price.
What were the biggest challenges of this project?
Building the extention at such a close proximity to our live facility provided operational challenges. To overcome these, a Swisslog project manager continuously managed interaction between contractors and Norbert Dentressangle colleagues. Another challenge was to transform the culture of our warehouse staff, from working with manual processes to automated.
How is your solution performing now?
Having now used the solution for eight months, we can confirm that it has fully met our expectations. There were no major problems faced during the project realisation and the system fully meets its expected productivity.
What are the advantages of your new solution? What has been the impact of the solution on your daily warehouse operation?
The new solution has enabled us to make considerable labour savings, since all pallet movements are now automated. Our goods reception is more efficient and our colleagues are more motivated by their new working environment!
How was it to work with Swisslog during the project period?
Swisslog worked as a general contractor. Their project management expertise ensured that we kept to the planned schedule and we were given a clear visibility of progress and costs. We enjoyed working together with Swisslog; their swift responses to every issue (no matter how big or small) was a key success factor of the project. Both Swisslog and Norbert Dentressangle invested in developing a strong relationship which has lead us to enjoy a mutually beneficial collaboration.
How is it to work with Swisslog at the moment?
Our partnership with Swisslog continues. We still have a strong collaboration between the two companies and receive support from Swisslog whenever needed.
How do you see the future for Swisslog and Norbert Dentressangle?
We fully intend on working together with Swisslog to maintain the solution. Built for growth, Swisslog has already informed us of future possibilities for our site – we may make some small modifications over the coming years in order to maintain full alignment to our customers‘ requirements. It will soon be time for us to look for a new challenge and why not together with Swisslog!
Swisslog
Tel: 01527 551 600
Email: wds.uk@swisslog.com
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