Food logistics of superlatives

Coop produces 60,000 tons of bread and baked goods at its new logistics site in Schafisheim. The wholesaler supplies 350 stores with food from there. Schafisheim is also the starting point for the national distribution of frozen products. In short: a logistical tour de force is performed here every day. "We have big plans," was the declaration of intent of Leo Ebneter, Head of Logistics at Coop, when the planning of a new logistics center was initiated around seven years ago. Today it is clear what dimensions he had in mind at the time: after three years of construction, a building complex has been created that sets new standards in food logistics.

The mammoth project is a milestone in the implementation of Coop's 2015+ logistics and bakery strategy. This in turn is part of the major distributor's CO2 vision, which envisages the entire company being largely CO2-neutral by 2023. This includes the gradual shift of transportation from road to rail. Coop already transports around two thirds of its goods by rail.

Concentration of three business divisions at one location

In the new building complex in Schafisheim, Coop has set up three divisions at a location with optimal transport and distribution links directly on Switzerland's economic axis. Firstly, the largest bakery in Switzerland and one of the most modern in Europe has been created here: Around 600 employees work in three shifts on traditional wood-fired ovens and high-performance systems with a high degree of automation. During the night, they bake fresh breads, cakes and tarts. During the day, they produce dough pieces - i.e. pre-made products from raw dough - which are frozen on site in the deep-freeze warehouse, distributed to the branches and baked there.

"What the new Gotthard Base Tunnel is for Switzerland, Schafisheim is for Coop logistics."

Joos Sutter Chairman of the Executive Board, Coop

The second area that Coop has located in Schafisheim is the national distribution center for frozen foods of all kinds with fully automated warehouse management and order picking. From here, Coop supermarkets and Coop Pronto stores throughout Switzerland are supplied with frozen pizzas and frozen vegetables. As a third function, Coop has set up a regional distribution center for the entire Coop range. Deliveries are made to around 360 sales outlets in the greater Zurich area and in north-western and central Switzerland. The logistics site also has an empties center where returns from the stores are collected and sent for further processing.

Construction project corresponds to the volume of 200 single-family homes

The Coop logistics center in Schafisheim was opened on 22 June 2016 after a construction period of three years.

The planning and realization of such an ambitious and complex large-scale project requires partners who not only have planning, logistical and construction expertise, but are also familiar with the specific framework conditions and requirements of the food industry. With a total investment of 600 million Swiss francs, a gross floor area of 240,000 square meters and a construction volume equivalent to around 200 detached houses, the qualifications of the planning partner are uncompromising. Coop decided to work with IE Food Engineering, part of the IE Group, which has proven its expertise in factory construction in the food sector in numerous projects.

Cooperation between experts from different disciplines

Despite many years of experience, the construction of the new Coop logistics center was a major challenge for the planning company simply due to its enormous dimensions and logistical complexity. The basic prerequisite for the success of the project was cooperative planning under the leadership and participation of specialists from the client and the engineers and architects from IE Food. The TGW Logistic Group, which specializes in internal logistics solutions, was also brought on board as an important partner. In total, around 200 specialists from a wide range of disciplines were involved in the project organization.

Construction project profile

Client: Coop-Genossenschaft Planning and realization: IE Food Engineering (IE Group Zurich and Munich) Project scope 5 new buildings: - Distribution center - National deep-freeze warehouse - Empties center - Industrial bakery and confectionery Number of project team members: 80 to 120 Gross floor area: 240.000 m2 Construction volume: 1.5 million m3 Foundation: 282 bored piles extending up to 23 meters underground Planning time: 5 years Construction time: 3 years Investment volume: CHF 600 million Energy production biomass power plant: approx. 14 gigawatt hours/year Electricity production solar power plant: 250,000 kilowatts/year

Focus on efficiency and sustainability

The Coop logistics center is an example of overcoming complex challenges in factory construction:

• Building structure developed from the function The planning approach "from the inside out" was also used in Schafisheim. At the end of the bakery's production lines, the deep-freeze center is located at the same height. The baked goods are transported directly to the deep-freeze warehouse and then to the distribution center via a passageway.
• Linking the intralogistics with the external logistics concept The timetables for the delivery and collection of the trucks, calculated down to the minute, set the pace for the internal logistics systems. In Schafisheim, the conveying processes, warehouse management, order picking and provision of goods have been automated as far as possible. State-of-the-art storage systems, shuttle vehicles, robotic and buffer systems are used.
• Building technology with ecological added value 70 percent of the ovens in the industrial bakery are heated with energy from the company's own biomass heating center. The main source of energy is organic grain waste from the Swissmill grain mill in Zurich. With sustainable energy generation, Coop reduces CO2 emissions by around 10,000 tons per year. The process heat from the bakery and the biomass power plant is also used in Schafisheim.

Thomas Hanhart