In an interview with Mats Tornard, Project Manager of Strategic Supply Chain at Coop, he talks about the project, its current status and Coop's goals for the future. He explains how and why Coop decided to switch from a completely manual warehouse to one of the largest automated distribution centers in the world.

How the 77,000 m² facility works
Coop's values were clearly communicated at the start of the project to avoid any compromises. The grocer puts its employees and sustainability at the heart of everything it does and took them into account in every decision made regarding the new site. For example, the delivery of goods will be linked to the nationwide rail network to reduce car use and therefore the carbon footprint.

The majority of goods will be delivered to the new distribution center by rail and unloaded outside of the dispatch area. The incoming goods area is equipped with conveyor technology including an NOK station and a pallet inspection station to check whether packing, positioning and load handling have been carried out correctly. The goods are then taken to the high-bay warehouse for temporary storage until they are needed for an order. At the depalletizing station, the individual cartons are unloaded from the pallets in order to store them and prepare them for the subsequent picking of customer orders.

The 3D matrix solution from SSI Schaefer, which the customer calls the "picking warehouse", will serve as a buffer for cases. The storage locations are served by SSI Flexi Shuttles, which are responsible for storage and retrieval. Depending on the order, the required palletizing sequence is automatically specified and controlled by the in-house SSI Schaefer logistics software Wamas, which guarantees both pallet stability and a minimum transport volume. The required cartons are delivered by the SSI Flexi Shuttle to the palletizing station, where a palletizing robot assembles the orders for shipping.

"Despite all the challenges that the pandemic has presented the market with, we are pleased that we are on schedule with the realization of the project and have had no delays so far," explains Mats Tornard. "We have just completed the construction of the distribution center. SSI Schaefer is now building the high-bay warehouse and the SSI Flexi shuttle racks. At the same time, we are also focusing on redesigning our internal processes to get the most out of the new system."

Advantages of the new system
"It is wonderful that both companies see this collaboration as a long-term partnership. We are pleased that SSI Schaefer is always keen to incorporate their new solutions that were not yet available during the planning and design phase. This proactive and innovative thinking will definitely help us realize the maximum potential of our distribution center," says Mats Tornard.

The new facility will enable Coop to increase the efficiency of its supply chain. Coop will greatly increase the number of orders dispatched each day and, thanks to the rail link, make transportation more accessible and easier to plan.

Coop wants to reduce the unloading time in the stores by providing store-friendly pallets and delegating palletizing to palletizing robots as part of the SSI Case Picking System. This will improve the current process and ensure faster and more stable pallet loading.

One of the key benefits of the solution is a safer and more ergonomic working environment. Currently, all processes involving the lifting and carrying of heavy loads or stretching movements are carried out manually. When the new solution is introduced, most of these demanding tasks will be automated. Humans will mainly take over monitoring and control activities. This allows Coop and its employees to shift the focus from potential health concerns to strategic considerations of what else can be done to improve the bottom line.

Sustainable future in sight
"Sustainability is one of Coop's core values," explains Mats Tornard. And it has been for years. For example, 30 years ago the company was the first grocery chain in Sweden to launch its own organic brand, Änglamark. The brand is known throughout Sweden and maintains its original, environmentally friendly approach. In 2020, Änglamark was named Sweden's most sustainable brand by the Sustainable Brand Index. This year, the award went to Coop again.

Mats Tornard continues: "We always consider ecological aspects before we start a new project." The new solution also brings the company other sustainable benefits. By merging refrigerated and ambient temperature storage areas into one building, Coop requires less transportation and therefore generates a lower carbon footprint. "Coop is a company with exceptional individuality, a sustainable approach and great care for its employees. SSI Schaefer shares the same values. This is one of the reasons for the successful and seamless collaboration between our companies. We are delighted to be part of such an exciting project," summarizes Michael Hillström, Managing Director of SSI Schaefer Sweden.

This article appeared in issue 3/2022.