Cost-efficient brownfield retrofit solutions

HOWEVER, THERE is also a trend on the market, both nationally and internationally, for brownfield solutions. This can involve both modernisations and expansions of technology and building. Consequently, it is a matter of transforming facilities that were previously used manually into automated logistics centres. 

There are many factors that speak in favour of making existing logistics structures fit for the future within a brownfield strategy and thus saving money and time. 

For example, if the existing distribution centre is already at the right location and is logistically well-integrated into the retail network in terms of stores and suppliers – with a good connection to the traffic route and rail network. The energy and communication systems are already in place and employees already come from the region – an enormous advantage in terms of retaining know-how, corporate culture, and recruiting. 

In addition, new building land is becoming scarce, as many communities are designating fewer and fewer commercial property due to their sustainability strategies. 

Add cost and time to market as key factors. Implementing technology into an existing building is cost-efficient – whether by modernising already existing components (racking systems, mechanics, conveyor systems, PLC + IT) or by completely integrating new innovative storage and picking solutions.

Verification

In order to evaluate whether the existing logistics facility is suitable for the future strategic approach, the first step is to obtain a thorough analysis and an end-to-end implementation concept. This includes the verification of the existing building structure / building fabric; and depending on the temperature zone, e. g. floor conditions, statics, clear height, technical building equipment including air-conditioning technology, available building areas, possible expansion areas, possible building expansions, etc.

You also need to evaluate the extent to which existing logistics technology can be modernised or is replaced, complemented by new logistics technology (e.g., OPM, AIO, ATS, GTP, shipping buffer, highly dynamic stacker cranes, and conveyor system, etc.)

The design of material flow processes 

In addition to the optimal connection of all logistics areas and temperature zones, typical building requirements are also being considered. These include, for example, good accessibility for service and maintenance teams, cleaning of the facility, fire protection, escape routes, or how the new technology can be physically implemented into the building in the best way (e.g., via the roof or by opening side walls). 

In the process, the most important question has to be clearly addressed: How will the project be implemented throughout the entire project phase – and how will the ongoing operation or delivery to stores and consumers take place at the same time.

Depending on the individual case, it is possible to use different approaches to implement this in a practical way either at the site or in the logistics network. 

Brownfield references worldwide

WITRON is very familiar with the requirement to economically map brownfield solutions with automated storage and picking technology. The company is considered one of the global market leaders in the design, implementation, maintenance, and system operation of highly dynamic distribution centres.

COOP in Norway, for example, has increased the output of its dry, fresh, and frozen food areas by 30% during ongoing operations at its multi-temperature distribution centre in Oslo by installing eleven additional COM machines, including corresponding infrastructure such as further pallet storage aisles, tray storage aisles, stacker cranes, stretch-wrappers, depalletisers, and conveyors, and now picks more than 625,000 cases daily. 

es in a store-friendly manner. Order picking is done on both pallets and roll containers. 

For more information, visit www.witron.com