Automated technologies from KNAPP are helping food retailers worldwide to fulfil online orders profitably.
The main challenge in grocery retail today is clear: the continuing rise in less profitable online orders in the face of labour shortages. The solution is automation but grocers need to ensure their investments achieve the productivity, flexibility and scalability they need to create competitive advantage.
KNAPP’s E-Grocer concept offers solutions for various population densities – from large central fulfilment centres (CFCs), through medium-sized suburban fulfilment centres (SFCs) to micro fulfilment centres (MFCs) for urban neighbourhoods. E-Grocer combines proven KNAPP technologies for the various grocery products in e-commerce orders. Fast-moving lines can be picked directly from pallets using voice or augmented-reality picking systems. Medium- and slow-movers, meanwhile, can be stocked in the high-performance OSR Shuttle™ automated store, with orders fulfilled at ergonomic workstations. With each picker able to fulfil four orders at once, fulfilment time is slashed – typically, a 50-item order can be completed in about six minutes, compared to an hour for manual picking. Once picking is complete, containers can be stored in an automated OSR Shuttle™ dispatch buffer, from where they are retrieved at the right moment and in the optimal sequence for dispatch.
Orders ready within 30 minutes
In addition to supplying grocery chains directly, KNAPP has partnered with Takeoff Technologies to deliver MFCs to some of the world’s largest grocers, including Albertsons, Carrefour and Woolworths. MFCs can be incorporated in existing supermarkets or operated as independent dark stores. They require as little as 13 weeks’ installation time, compared to 18-24 months for a CFC. Customer orders can be ready for pick up or delivery within 30 minutes. For example, French supermarket chain, Intermarché operates two MFCs equipped with KNAPP automation as dark stores, preparing online grocery orders in the Paris and Lyon conurbations. They offer customers three options for the last mile: drive-in pick-up, 24/7 collection from lockers or home delivery.
Robotic picking
E-Grocer solutions in MFCs, SFCs and CFCs can also incorporate KNAPP’s AI-enabled Pick-it-Easy Robots. These robots are able to fulfil orders with a high degree of accuracy and at speeds equivalent to manual picking stations, yet maintain this speed over much longer periods. Using AI and intelligent sensors, the robots not only self-teach to recognise different packaging or features and determine the optimum grip point, but also share their learning worldwide. This means they can handle a broad range of groceries gently, rapidly and reliably. They place heavier, less delicate food items in bags first, with lighter items placed on top.
Robotic picking is being deployed by Shufersal, the largest supermarket chain in Israel. Two automated CFCs – in Kadima and Modi’in – have secured the retailer an automation level of almost 100% for its online operation, Shufersal Direct. The company is also benefiting from some further innovations from KNAPP. Firstly, its automated storage system is the first OSR Shuttle™ Evo project worldwide engineered for frozen items. Secondly, KNAPP has supplied unique solutions for automating the goods-in and order start areas. Robots are used for decanting, automatically opening cartons and placing items into containers for storage in the OSR Shuttle™ Evo system. Then, in a market first, automated technologies are used to open the paper delivery bags and place them in the containers with their flaps folded so that they stay open.
As the demand for MFCs (around 10,000 square feet) begins to rise, Takeoff Technologies is now also developing ‘Nano Express’ facilities (around 2,000 square feet). It is clearly a fast-evolving market but what is also clear is that automation – by enabling faster fulfilment, reducing operating costs and mitigating labour shortages – will play a vital role in making online food retail profitable.
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