For food and beverage manufacturers, maintaining an efficient supply chain is critical – especially when handling perishable goods.
Between the bulk storage of full pallets and the final assembly of customer-specific orders, manufacturers face logistical challenges that can impact both efficiency and product integrity.
Case buffer systems help bridge this gap, optimising space utilisation, and ensuring compliance with stringent cold chain regulations.
“Cold chain regulations include strict rules about how long meat and other produce can come out of a frozen environment before it impacts freshness, so having a system that can give you total visibility and better control is a major asset,” says Joseph Kutek, Sales Consultant, Food and Beverage, Swisslog Australia and New Zealand.
Swisslog is a global warehouse automation provider with more than 250 deep freeze projects worldwide.
“With an automated case buffer system like Swisslog’s CycloneCarrier in place, food and beverage processors can gain better control of batches and best before dates, thereby delivering orders with the highest levels of freshness to customers,” says Joseph.
CycloneCarrier provides storage up to four positions deep (quad deep) for totes, trays or cartons and is suitable for deep-freeze storage environments. It can perform up to 2000 movements per hour, per aisle, with each case able to hold up to 50kg.
“A major advantage of using an automated system like this is energy efficiency. In temperature-controlled environments, storing more cases in less space will reduce cooling costs. Additionally, with fewer operators moving in and out of the environment, the cooling system can operate more efficiently,” says Joseph.
“CycloneCarrier is a dynamic system, so if a lower performance is required, the system will automatically slow down. This will reduce wear and tear on the system saving operating costs.
“Another option for food and beverage manufacturers seeking efficient vertical storage is Swisslog’s Tornado miniload crane, which is ideally suited to reserve storage and replenishment of manual picking zones, as well as feeding goods-to-person pick stations directly, including temperatures down to zero.”
End-to-end automation
In cold chain applications, once the product has moved through a blast freezer, it is typically transferred to a light goods conveyor, such as Swisslog’s QuickMove Conveyor system, then on to the case buffer, and then to robotic palletising.
“Because Swisslog is part of the KUKA Group, we are uniquely position to provide an end-to-end solution, including KUKA’s automated palletising robots for the final stage of the process,” says Joseph.
“Most of these projects are brownfield, so it’s important to consider the material flow at the end state, and how to make the best use of existing space. Having experience in each of the different stages means Swisslog can take a holistic view and find the best efficiencies.”
Staying in-SynQ
Controlling a case buffer system is Swisslog proprietary SynQ software, which can perform the role of a Warehouse Management System, Warehouse Execution System and Warehouse Control System.
“SynQ provides total visualisation of the system in real-time, and allows for efficient and accurate troubleshooting, as well as optimising performance over time. It can, for example, position faster-moving products nearer the front of the storage system, for quicker access,” explains Joseph.
“SynQ is a single platform that uses proven industry-specific processes that optimise warehouse automation processes, backed by more than 100 years of experience, with more than 500 software experts worldwide.
“Swisslog also has customer service teams that can provide preventative maintenance and ongoing support to maximise the life of the system.”
The future of food and beverage logistics
As the food and beverage industry continues to evolve, automation and smart storage solutions are playing an important role in ensuring efficiency, compliance, and sustainability. By adopting advanced case buffer and palletising technologies, manufacturers can optimise their supply chains while maintaining the highest standards of product quality and freshness.