Kaufland Automates Logistics Center Geisenfeld

At a height of 30 meters, small shuttle vehicles glide automatically over their long tracks, storing goods in and out. In a constantly changing rhythm, robotic arms pack pallets as needed for around 125 Kaufland stores in southern Germany. Like guided by ghostly hands, autonomous transport units, resembling moving phone booths, deliver completed pallets to the goods exit.

(Neckarsulm/Geisenfeld) The logistics world of tomorrow can already be seen today in Geisenfeld, Bavaria. After more than three years of extensive expansions and a successful ramp-up phase, the storage processes at Kaufland’s logistics center have been largely automated since September. With the newly commissioned high-bay warehouse, capacities can be increased without consuming additional space, which often no longer exists. At the same time, delivery reliability is enhanced.

“You don’t transform a logistics location overnight. That’s why we consciously decided years ago to redesign our location in Geisenfeld into a nearly fully automated high-tech warehouse. The technology and robotics have been developed and integrated specifically for the site. We have gradually introduced the new technologies in the individual storage sections over the past years. Geisenfeld now houses one of the most modern logistics centers in the German grocery retail sector,” says Konrad Ott, Project Manager Automation Geisenfeld.

Automated Order Picking of Over 200,000 Items Daily

In the food sector, up to 185,000 items are automatically picked. This means that after delivery, pallets are automatically stored in the high-bay warehouse by storage and retrieval machines and kept there until the goods are needed. Depalletization is also mostly automated. Twelve robotic arms then assemble the pallets according to the specific needs of each store. They arrange the goods so that employees in the store can directly stock them in the correct order.

The autonomously and manually packed pallets are fully automatically packed and wrapped, and then transported in the correct order via autonomous transport vehicles towards the goods exit. The transport robots are equipped with state-of-the-art sensors, cameras, and motor technologies that help them track the optimal route and navigate safely around people and objects.

In addition to the high-bay warehouse, Geisenfeld has an automated order picking system (AKA) for fruits and vegetables. The system can handle up to 50,000 items per day and can process different combinations of various transport boxes. All freshly delivered fruits and vegetables only need to be placed in the machine, and then boxes of salad or bananas are removed from the pallet and individually assembled for the stores via the AKA.

Trained Own Employees for the New Technology

The automation greatly facilitates the daily work of the employees on-site. With the use of robots and mobile shelves, for example, walking distances and strenuous tasks are eliminated. Robots provide ideal support, especially for heavy goods. This allows pickers to focus more on tasks such as goods control and loading sensitive items.

Additionally, there are new, exciting tasks. The latest technology is being used in Geisenfeld, which means that digital minds are also needed in logistics. 90 percent of the required employees for control, maintenance, and repair positions have been filled through the further training of pickers.

Photo: © Kaufland