Reliable partner for value-added warehouse automation
Wide selections of high-quality products, excellent service and rapid deliveries – consumer demands are vital considerations in the warehouse automation market. Vanderlande is a major player in the industry and specialises in solutions for food retail, fashion, parts and components, and e-commerce. It cooperates closely with its customers to optimise their supply chain and enhance the efficiency of the processes in their distribution centres.
Many of the world’s largest retailers, wholesalers and e-commerce operators rely on Vanderlande’s vast experience in the automated warehousing market. It has completed or managed ultra-large automation projects for the world’s biggest food retailers, and its integrated material handling systems are operated by leading global fashion brands.
An impressive track record has enabled Vanderlande to build strong relationships with top wholesalers in sanitary, heating and ventilation parts and components. These include the supply of systems on multiple sites for warehousing giants.
Vanderlande identifies industry trends and developments to help its customers acknowledge and respond to the challenges they are facing in the market. Its solutions for automated warehouses and distribution centres meet their specific needs with best-in-class processes to ensure the completion of deliveries on time, and the lowest total cost of ownership.Value-added warehouse automation
This integrated approach extends from an analysis of the initial business process to a comprehensive life-cycle services programme, resulting in an optimum performance throughout the system’s lifetime.
Goods receiving is the basis for all other warehouse activities. It is important to receive products correctly in order to handle them appropriately for put-away, storage, order picking or shipping. After unloading, Vanderlande’s VISION warehouse management system drives the identification, checking and registration of products. The functionality includes handling of returns, unexpected goods and repacking. Goods are directed to storage, order picking or directly for shipping through a cross-docking process.
Depending on product velocity and specific characteristics, goods can be stored either on pallets or trays, and in cartons or totes. They can be automatically directed for storage or order picking, minimising manual handling and providing speed and efficiency in replenishment and supply.
A number of companies, including La Halle – Vivarte, Onninen and Argos have already trusted Vanderlande to deliver automated goods receiving solutions.
In addition to faster and more efficient loading and unloading, the telescopic belt conveyor vastly improves ergonomic working conditions for operators. The extendable variation minimises the need for operators to carry products manually and places drop-off points at their side on demand by a simple joystick movement.
Vanderlande has implemented telescopic belt conveyors (extendables) at Argos, Casaventa, NG2 and VF Europe.
It facilitates the efficient and ergonomic repacking/receiving of items (from cartons) into totes. In addition, it offers various levels of automation (for higher productivity levels) and receiving into single and multi-compartment totes.
Each variant of the RECEIVE@EASE workstation is geared towards specific productivity and functional process requirements. They have been designed in line with the ergonomics of the PICK@EASE range with the support of Dutch research institute TNO, and implemented for a number of customers, including Onninen. The benefits of RECEIVE@EASE include:
Automated cross-docking is especially beneficial for fresh products to ensure product quality. Vanderlande has implemented automated cross-docking systems for food retailers, such as E.Leclerc.
The system is especially useful for push flows to create a fast fashion model when handling apparel and footwear. Automated cross-docking is also gaining popularity for dealing with high-tech products and electronics to achieve a short time-to-market window.
Vanderlande’s cross-docking system, based on automated sortation and VISION software, has a wide range of benefits, including:
Warehouse operations are coming under increasing pressure due to labour scarcity, expensive floor space and higher customer demands for delivery response times and accuracy.Vanderlande recognises the important role played by automated storage and retrieval systems (AS/RS) in meeting the tough demands of any logistics operation. The company’s solutions help to maximise efficiency and productivity in distribution centres and make optimal use of floor space.
Vanderlande’s complete range of AS/RS includes miniloads, shuttles and load-handling devices that integrate seamlessly into existing operations. These systems can handle different types of products, such as pallets, totes, trays, cartons and even car tyres. The company’s experience in logistics and material handling is an invaluable resource when deciding on the most appropriate solution for individual requirements.The AS/RS have been implemented in a wide range of industries for more than 300 well-known companies, including Van Den Ban, Audi and Kaufland.
This system can achieve extremely high throughput rates, and is especially suitable for the highest capacity goods-to-man order picking and consolidation processes. This is due to its ability to access all goods quickly and deliver them when required, which also helps to improve operator efficiency.
The shuttle system is a cost-effective solution for short-term storage of order totes. Store-friendly delivery is facilitated by the automatic presentation of totes/cartons in the required sequence for stacking on pallets or roll cages. The result is fast, efficient order consolidation with minimum manual labour requirements.
The QUICKSTORE HDS has been implemented in a wide range of industries, such as parts and components, food retail and e-commerce. A number of companies have already installed this particular system, including Zalando, Edeka, Onninen and Tesco.
The company offers a range of standard miniloads and load-handling solutions, including: single or double-deep storage; single or double mast; single, double or quadruple shuttles; and load-handling devices based on belts, telescope or vacuum telescope.
Vanderlande’s BARRACUDA is a highly reliable load-handling device for multi-deep products in post-beam racking. It handles cartons, totes and trays of variable dimensions in a form-locked, positive way, which guarantees maximum availability.
Selecting the appropriate miniload AS/RS depends on the storage capacity and required throughput. Vanderlande’s miniloads have been implemented in a wide range of industries, such as parts and components, automotive, food, fashion and non-food. More than 1,000 miniloads have already been installed for companies, including Tommy Hilfiger, Herma and GAME Stores.These solutions offer a range of benefits, including:
By sorting pallets in automated storage and retrieval systems (AS/RS), or pallet high-bay storage, a reduction in handling can be achieved. Optimum use of available floor space is also a benefit. Various types of (semi) AS/RS solutions can be integrated for (temporary) storage of raw materials or (semi) finished products.
Traditionally pallets are stored in racks, flow racks or block stacking and picked by forklift trucks. Automated pallet-picking systems can deliver significant benefits by ensuring constant capacity and careful product handling.
When combined with pallet conveyors and sortation systems, this can provide a fully automated pallet-picking process. Vanderlande has already implemented these systems with Argos, Colombini, Arrow Electronics, Edeka and Tchibo.
The MICROSHUTTLE is an automated storage and retrieval system and part of Vanderlande’s QUICKSTORE range of miniloads, shuttles and load-handling devices. The shuttles are not dedicated to one storage level, but can move between different levels in the racking via a lift. They make use of capacitors – ensuring they can operate autonomously, without the need for power rails in the aisles – and utilise wireless communication.
Scalability and flexibility
Each MICROSHUTTLE system can grow with an inpidual business and match the required throughput. For example, a system with 12 levels can start with only two shuttles, keeping the initial investment low. As throughput requirements increase, shuttles can be added inpidually until the maximum lift capacity is reached.
Cost effective and energy efficient
During the development of the QUICKSTORE MICROSHUTTLE, much attention was paid to minimising weight, with the design geared towards a lightweight, energy efficient and cost-effective system. The optimum combination of motor performance, acceleration and speed ensures energy efficiency.
Scalability and availabilty
ADAPTO makes optimal use of available space in warehouses, while extending or adding aisles to increase storage capacity and the system remains operational. The throughput of an existing ADAPTO can be further increased by adding MICROSHUTTLES and/or lifts.
In addition, ADAPTO ensures easy access to products at all times. This is not affected by lift or shuttle unavailability due to the way in which each shuttle can reach every location in the system.
Maintainability and sustainability
Maintenance platforms allow quick operator access to all shuttles and rack locations, enabling fast and safe troubleshooting. If operator intervention is required, the problem area is isolated, affecting only a minor part of the system.
A multi-layer safety system allows operators to work safely inside ADAPTO, while the seperate maintenance workstation (where shuttles can drive to themselves) has been ergonomically designed for engineers. This helps to keep running costs and energy consumption low.ADAPTO is a 3D product that consists of the following components:
Order picking – also known as order fulfilment – is the process of retrieving products from storage in order to meet a specific customer demand. Processing orders rapidly and accurately has a direct impact on customer satisfaction.
Selecting the best order-picking solution depends on the requirements of inpidual operations and products. Vanderlande’s experience and expertise in designing and implementing these systems takes into consideration such criteria as volume and item velocity.
These integrated order-picking systems ensure each product is picked via the most suitable method. Attention will also be given to whether they will handle inpidual items, full cases or pallets. Vanderlande has already supplied these systems to companies such as Amazon, Arrow Electronics and Nike.
At the heart of the CPS is the PICK@EASE ergonomic order-picking workstation. This innovative workstation enables operators to achieve a consistently high order-picking performance – up to 1,000 order lines per operator per hour – over a prolonged period. This is also achieved without risk of any work-related injuries.
CPS takes advantage of the QUICKSTORE family of automated storage and retrieval systems. These miniloads and shuttle systems automatically store and retrieve product totes, and make optimal use of available floor space.
Vanderlande’s goods-to-man order-picking systems are supported by the VISION warehouse management system, which ensures the effective handling of the entire warehousing process. Companies, such as PLUS Retail, Onninen and TVH, have already installed Vanderlande’s CPS solutions.
Zone picking is a man-to-goods order-picking concept that can be used for a wide range of applications. Vanderlande’s zone-picking system (ZPS) provides a reliable, accurate and structured process, with short order throughput times.
The picking area is pided into inpidual pick zones, and operators assigned there will only pick items within that zone. Products in a zone can be stored in flow racks or shelving.
Once picking in a zone is complete, the order tote or carton travels via a conveyor to the next zone (pick and pass). This system reduces walking distances during picking and eliminates crowded picking aisles during peak hours. It is highly efficient, owing to the way in which operators can pick directly into shipping cartons or totes (pick and pack).
Vanderlande has a broad experience of designing and implementing ZPS, which can be supported by a number of methods within the VISION warehouse management system (WMS). These include, paper based, RF terminals, Pick-to-Light and Pick-by-Voice. Other WMS functions related to zone picking are slotting, replenishment strategies, order planning and release, and integrated checking.
Vanderlande’s picking systems have already been implemented at many companies, including DA Retail, Rossmann and Fabory.
Vanderlande’s automated case picking (ACP) systems provide the tools to outperform traditional order fulfillment methods. These improvements not only benefit distribution centres, but also the efficiency of the processes at work in stores. Vanderlande’s ACP design is setup to allow modular growth and ensures availability by utilising parallel activities.
The service levels of a supermarket are highly dependent on the quality and speed of its replenishment systems. When the store orders a shipment from the distribution centre, it is essential that the pallets are selected in the same sequence of product groups as the store’s layout. Before the pallets are stacked, the load forming logic software defines an optimal stacking pattern, with this product group sequence in mind.
It also defines staple pallets that are filled with maximum efficiency, so that the transport volume is minimised. The finished pallets will be wrapped and transported to stores, where there will be no need for extra sortation and they can be used immediately to fill the shelves.The Load Forming Logic (LFL) software ensures:
In the automated distribution centre, a robot with a special mechanical gripper is used to take full layers of product from the pallet. The layers are then deposited on a conveyor system, where inpidual products are oriented correctly by a series of processes. Safe handling in the storage system is ensured by a 3D-measuring system that uses laser technology.
Pallets can be picked from pallet high-bay storage with an automated storage and retrieval system. When combined with pallet conveyors and sortation systems, this can provide a fully automated pallet-picking process. Vanderlande has implemented pallet-picking systems at Argos, Colombini, Arrow Electronics, Edeka and Tchibo.
Batch picking increases both throughput and operator efficiency. It optimises order-picking effectiveness by maximising pick quantities and minimising operator walking distances. Orders are either sorted/consolidated by order or destination automatically, which reduces manual handling and the problems normally associated with congested aisles in traditional order picking.
Vanderlande’s batch picking systems are supported by the VISION warehouse management system for the effective handling of the entire process. Functionalities include batch and resource planning, sorter control and a dashboard to display key performance indicators.
The company has broad experience of designing and implementing batch-picking systems, for companies including Amazon, Game Stores, Euro Shoe and Staples.
Picking takes place with virtually no manual labour. This type of solution is especially beneficial for fresh food in a retail environment, such as meat, poultry, deli, fruit, vegetables and dairy products. Examples have already been installed at Micarna, Edeka and Hilton Meat.
Vanderlande offers a range of sortation systems tailored to inpidual business processes, products, required throughput, and the volume and nature of sort destinations.These systems consist of both line sorters (sliding shoe sorters, pusher sorters and pop-up sorters) and loop sorters (cross-belt sorters and tilt-tray sorters). Vanderlande has implemented automated sortation systems at many well-known companies such as Amazon, Urban Outfitters and Edeka.
It is used mainly in batch-picking processes and cross-docking systems, and as a shipping sorter. It has capacity for up to 18,000 carriers per hour. Vanderlande has a range of CROSSORTERs, which include the 700, 1200 and 1500 versions.
The company is committed to ensuring materials are used in a way that ensures their return into technical or biological cycles. The CROSSORTER is built using sustainable materials, consisting of technological or biological materials that are safe and healthy for both humans and the environment.
The company has implemented cross-belt sorters at many well-known companies, including Nike, Urban Outfitters, Marie Claire and GAME Stores.The following results have been achieved with the CROSSORTER:
Vanderlande has implemented POSISORTERs at many well-known companies, such as Argos, Edeka and Staples.
The modular design means the TRAYSORTER is fully scalable and the configuration can be adapted to inpidual requirements. It can also be adjusted to fit into existing warehouse architecture.
With a low initial investment, the TRAYSORTER is an affordable and innovative sorter that helps to boost a facility’s overall performance. The optimum design of the modules results in the smallest footprint concept per sorted item and a favourable ROI.
Several tray types are available:
Automated order consolidation and shipping can significantly enhance the efficiency and speed of an outbound operation. It can also enhance store-friendly delivery and reduce transport costs by optimising the loading of dollies, pallets and roll cages.
Material flows from different (order picking) areas come together in an automated storage and retrieval system. Vanderlande’s shuttle systems (MICROSHUTTLE, ADAPTO and HDS) are cost-effective solutions for the short-term storage of order totes and cartons. Due to its high capacity, QUICKSTORE HDS is most suitable for this purpose.
Within a short time period, flows can be sorted and grouped per order, delivery unit or shipment, and then dispatched in the precise sequence required. The result is fast, efficient order consolidation and store-friendly delivery with minimum manual labour requirements.
Automated shipping sortation
By implementing automated shipping sortation systems, goods can automatically be directed to a lane associated with a retail outlet, delivery route or provider, and geographical area. This significantly increases efficiency, improves accuracy and reduces the costs per carton, or tote, handled.
Vanderlande has installed automated shipping sortation systems at many companies, including, Casaventa, Nike, Staples, Colombini and Herma.
Packing systems with PACK@EASE workstations can be integrated with other picking concepts or delivered as stand-alones. These solutions enable customers to organise their processes in the most efficient, cost-effective way.
PACK@EASE workstations have been designed on the same ergonomic basis as the PICK@EASE range in cooperation with the Dutch research institute TNO.
This solution has been installed for a number of companies, such as Life Technologies.
The main benefits of PACK@EASE are:
In the near future robotic technology will be developed for other market segments, such as baggage handling; parcel and postal; fashion; and parts and components. This will be mainly in warehousing, with automatic item picking and ULD loading as examples of promising applications offered to Vanderlande’s customers. Robotic technology provides a number of benefits:
The success of automated storage, order-picking and sortation systems depends on their reliability and cost effectiveness, or the internal transport that connects all logistic processes. The .M conveyor range is designed specifically to meet these requirements.
To enhance the effectiveness of warehouse operations, Vanderlande has
developed VISION, a warehouse management and control system. It includes:
turnkey solutions for material flow handling; user applications for picking,
counting and exception handling; and management functions in a web-based
supervisor application (business process installation).
The system supports value-added services and different user interface technologies, such as RF terminals, pick-by-voice and pick-to-light. VISION also offers extendibility, scalability and flexibility, which ensures investment security to highly automated warehouses.
In the fast-moving world of fashion and footwear, flexibility and value-added logistical solutions are of vital importance. Due to the explosive growth of e-commerce, the fashion industry is moving increasingly towards an omni-channel approach that consolidates all of the different facilities in multifunctional distribution centres.
In order to maintain their competitive advantage, companies operating within this sector rely on Vanderlande’s systems to respond to rapidly changing styles, consumer demand and seasonal trends. They also have to handle expanding product ranges – increasingly being sourced from the Far East – for efficient ‘push’ (stock replenishment) and ‘pull’ (ship to order) flows.
Its integrated material handling systems are trusted by leading global fashion brands, such as H&M, Nike, Next, Urban Outfitters and Tommy Hilfiger, to optimise their apparel and accessories warehouse logistics.
Vanderlande’s value-added approach to the design and implementation of automated warehouses in this sector includes the following solutions.
Most e-commerce distribution centres are challenged to fulfill thousands of orders with ever-shrinking lead times. The trend for next-day and even same-day deliveries is increasing, which restricts the order picking and packing process to around 30 minutes. The rapid growth of online sales across many retail sectors – from groceries and fashion, to electronics, music and books – means that large quantities of small orders have to be handled on a daily basis.
Customer satisfaction is of the utmost importance, which means error-free order picking is vital. In addition, a high proportion of customer returns (up to 30% of shipped products) must be handled by these state-of-the-art distribution centres. Vanderlande meets customers’ requirements with an omni-channel approach, consolidating all of the different facilities in multifunctional distribution centres.
The company’s efficient and accurate solutions are designed to help e-commerce businesses overcome these challenges and deliver a positive customer experience. These value-added solutions include batch picking and sortation, zone picking, compact picking (goods-to-person) and consolidation.
Vanderlande is a market leader for e-fulfilment, with a proven track record for ‘bricks-and-mortar’ as well as ‘bricks-and-click’ companies, such as Amazon, H&M, Littlewoods, Asda and Zalando.
In the food retail sector, consumers demand a wide selection of fresh, high-quality produce and excellent service. As a result, these retailers are facing significant challenges in their warehouse logistics.
Low margins make it necessary to reduce the cost per case handled and improve downstream efficiency. Store-friendly deliveries can significantly reduce supply chain costs and enhance the service levels to each retailer. In addition, point of sale information may trigger shorter lead times, or the need for more frequent and reliable deliveries, and the ability to handle peak in-store selling times.In response to changing market demands, Vanderlande has shifted the emphasis from a logistical solution to value chain optimisation. The company’s value-added systems enable fully automated:
Transportation costs can also be reduced by improving the pallet-fill rate with the help of a store-friendly delivery system for multiple retail formats. Goods-to-man (also called Goods-to-person) systems can be employed for slow-moving items or family groups, and cross-docking systems are especially suited for fresh products.
Many of the world’s largest retailers, wholesalers and e-commerce operators rely on Vanderlande’s vast experience in the automated warehousing market. It has supplied ultra-large automation projects to the world’s biggest food retailers, including Asda, Tesco, Carrefour and E.Leclerc.
Warehouse logistics for technical items, components and spare parts have challenging customer requirements. Next-day delivery, late cut-off times for orders and value-added services are essential. Large numbers of different items have to be stored and maintained, placing specific requirements on the tracking and tracing of serial numbers within the material handling system. The bottom line means that it is vital to have a low cost per case handled and optimum downstream efficiency.
User-friendly deliveries can significantly reduce supply chain costs and enhance service levels to stores. Common solutions for parts and components are zone picking and goods-to-man (also named goods-to-person) systems, including miniloads, shuttles and ergonomic workstations.
Shuttle technology has become the preferred solution for this sector, due to its versatility. Vanderlande’s ADAPTO shuttle concept combines ultimate flexibility with excellent integration of ergonomic workstations for order picking.
An impressive track record has enabled Vanderlande to build strong partnerships with top wholesalers in sanitary, heating and ventilation parts and components. These include the supply of systems on multiple sites for warehousing giants such as Bosch, Würth, Fabory, Arrow Electronics, Sonepar and Ahlsell.