Retailer provides fresh product on the shelves

With an output of 96,000 totes on a peak day Witron's DPS system helps Belgian retailer Delhaize supply more than 800 stores with more than 2,500 fresh lines on a daily basis

With domestic sales of 4.6 billion euro, Delhaize is the leading food retailer in Belgium. One of the reasons for its impressive growth is the company's competitive advantage in fresh logistics.

This is greatly helped by its use of automated solutions. In a recent example, Witron was selected as general contractor to design and implement a state-of-the-art logistics centre in Asse Zellik, Belgium. On a daily basis Delhaize supplies more than 800 stores with more than 2,500 fresh lines. Since autumn 2009 the Witron DPS system output on a peak day is 96,000 totes and is shipped to stores on dollies (DC Project Fresh II).

At the end of December 2011, Delhaize gave Witron a further order for the automation of full tote handling (DC Project Fresh III). The new logistics centre with an area of 12,000 sq m is directly connected to the DC-Fresh-II Building. The material flows of DC Fresh II and DC Fresh Fresh III are connected through their IT and conveyor systems. This allows efficient order consolidation to take place between the two buildings.

Automated Tote System As part of the system selection Witron impressed the Belgian food retailer with its patented, fully automated solution ATS (Automated Tote System). A major benefit of ATS lies in the fact that this system is able to store and pick commonly used Euro Pool totes without human intervention.

The Delhaize logisticians also wanted to increase throughput figures and it was decided to supplement the existing Witron DPS system in the logistics centre DC Fresh II with a further pick-module consisting of four lanes with 42,000 containers, eight stacker cranes and 12 workstations.

With ATS the entire material flow is significantly simplified and accelerated. In total there are almost 900 different fresh and ultra-fresh products in the temperature range +2 degrees Celsius and +4 degrees Celsius that will be delivered and picked as full totes. In the receiving area the complete shipment is identified with a single barcode scanning. Further processing in the system is ensured by indirect target tracing, making complicated labeling of individual totes with a barcode or similar unnecessary. Due to the flexibility of the system, Delhaize is able to use different tote formats with different base surfaces of 600 x 400 and 400 x 300 with different heights.

Award winning The redesign of the entire Delhaize supply chain for fresh logistics was a huge success. Witron contributed its share through the implementation of the project DC Fresh II. The Belgian food retailer was recently awarded for its "fresh optimisation project" by the Belgian Association of Logistics VIB PICS winning the "Supply Chain Award 2011 - SC Project of the Year" award. This future oriented, optimal structured logistics - from the supplier, through the distribution centre, transportation and up to the shelves at the retailer allows very short but highly economical delivery cycles. Therefore Delhaize customers are guaranteed that with every purchase of sensitive goods with short shelf life, they always have access to the freshest products. The store itself contains virtually no stock - a significant competitive advantage.

DC Fresh III is scheduled to open at the end of 2013. As a general contractor Witron is, as well as taking care of the design of the project, also responsible for the supply and ramp-up of all IT, PLC and mechanical components. The complete service & maintenance plan is performed by a Witron on-site team that keeps the system operating at an optimum level.