BT-Systems Realizes High-Bay Warehouse for Sofidel in Minnesota

BT-Systems, a leading provider of logistics and automation solutions, is making a milestone in the world of intralogistics: As part of an extensive expansion project by Sofidel in Duluth, Minnesota, BT-Systems will realize a state-of-the-art, fully automated warehouse with 35,000 storage locations.

(Ludersdorf-Wilfersdorf/Duluth) The project, which is part of a total investment of over 200 million US dollars, showcases the innovative strength and expertise of BT-Systems and its competence center ECE-LOG in the development and implementation of customized logistics solutions for international markets.

The new automated warehouse in Duluth will be equipped with the most advanced technology: five high-performance stacker cranes and innovative double-mover shuttles that can simultaneously move two pallets of 750 kg each, ensuring an efficient and fast material flow. The combination of multi-deep racking systems and a reduced number of aisles significantly maximizes storage density and reduces space requirements. This enables Sofidel to quickly and efficiently meet the increasing demand for sustainable hygiene products.

“With this solution, we offer Sofidel a state-of-the-art and efficient system that not only optimizes space but also significantly reduces operating costs and energy consumption. The project in Duluth represents an important step in the further development of our long-term partnership,” explains Thomas Lafer, head of the ECE-Log competence center at BT-Systems.

Innovative Conveyor Technology for Maximum Efficiency and Sustainability

BT-Systems has developed a customized conveyor technology solution that enables not only fast transport capacities but also resource-saving logistics. The intelligent transport system and optimized storage structure contribute significantly to increasing the energy efficiency of the entire system, which plays a key role in the current era of sustainability and resource conservation.

The newly constructed warehouse will be optimized by innovative warehouse management software and a powerful PLC control system from BT-Systems. These technologies ensure a smooth integration of the entire material flow between production and storage and enable precise, automated management of inventory.

General Contractor with 360° Responsibility

As part of the project, BT-Systems takes on the complete planning, implementation, and integration of the logistics solutions as the general contractor. The responsibility includes not only the construction of the warehouse and the integration of the racking systems but also the entire conveyor technology and fire protection solutions, including sprinkler systems. The ECE-LOG competence center of BT-Systems is responsible for the entire warehouse management software and control technology. Another advantage for Sofidel is the close local presence of BT-Systems through the REDWAVE competence center in Atlanta, USA. This allows for quick and efficient on-site support, which is crucial for the successful completion of the project and the long-term maintenance of the system.

Successful Collaboration: From Poland to Duluth

The partnership between BT-Systems and Sofidel has existed since 2018, when BT-Systems realized an innovative, fully automated warehouse with 32,000 storage locations in Poland. This project establishes the highest safety standards, with an innovative oxygen reduction technology that prevents fires and protects the stored products. A fully automated AGV transport system was also implemented there, which has ensured fully automatic internal material flow since 2021.

“We are proud that Sofidel is once again relying on us. The project in Duluth confirms that our customized and sustainable solutions meet the complex requirements of the global market,” explains Gerald Kreiner, managing director of BT-Systems GmbH. “With our competence centers in Austria and our branch in the USA, we are not only technologically leading but also able to reliably and personally support our customers on-site – quickly and efficiently.”

Future-Oriented Logistics Solutions for the Industry

With the project in Duluth, BT-Systems sends another signal for the future of intralogistics: Automation, sustainability, and energy efficiency play a key role. BT-Systems remains a reliable partner for customized logistics solutions that meet the demands of a dynamic market and set pioneering standards. The completion of the state-of-the-art, automated warehouse in Duluth is planned for 2026.

Photo: © Sofidel