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Case Study | Order Processing
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Food firm increases picking speed by 60% using intelligent sorting system

Swiss poultry-products specialist KNEUSS Güggeli needed a way to sort and pick products faster, for less cost.

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Kneuss Güggeli factory building

Challenge

  • An inefficient order-picking process was slowing down production.
  • Manual processes led to high labor overheads and a greater chance of manual error.
  • The extra space and time required for manual processing was inhibiting growth. 

Solutions

Stöcklin Logistik AG installed a solution with Rockwell Automation technology, which included:

  • A smart, affordable, safe commissioning system based on Rockwell Automation MagneMotion.
  • Three packaging and labeling lines, able to handle orders for up to 35 customers, simultaneously.
  • Increased flexibility allows KNEUSS Güggeli to handle small, quick turnaround orders more efficiently. 

Results

  • The new system reduced the space needed for order processing at KNEUSS Güggeli. 
  • It allowed the company to improve labor productivity by 15%.
  • The new system increased the speed of order picking from 25 to 40 packages per minute.

Swiss firm KNEUSS Güggeli is one of Switzerland’s leading poultry processors. It supplies its specialist poultry products to retailers and food outlets across the country. But with such an extensive customer base and product range, customers regularly order products in small non-standardized batches. 

Each delivery contains a different selection and number of products — both when compared to other customers and other orders from the same customer. With an old-fashioned, conveyor-belt and manual sorting and picking process, preparing shipments for delivery was time-consuming, expensive, and prone to human error.

The switch to MagneMotion: fast, accurate and safe

Leaders at KNEUSS Güggeli knew they had to solve the problems in order processing. The old process was inefficient. It relied too heavily on human sorting. Given the complexity of the process, with no two orders ever the same, this increased the need for checking, inflating the labor overheads of an already labor-intensive workflow.

The only choice

To solve this problem, KNEUSS Güggeli called in Stöcklin Logistik AG, an OEM that specializes in material-handling technologies for precisely this kind of challenge. Stöcklin’s engineers took one look at the requirements and realized they were up against a challenge.

“We were faced with the need to accelerate the speed at which KNEUSS Güggeli could process packages, but to do so in a smaller space, without increasing the exposure of workers to hazards such as the fast-moving machine parts or excess noise levels,” explained Max Studer, lead engineer at Stöcklin. 

Once his team understood the scope, nature and scale of the challenge, the solution was obvious. “It had to be Rockwell Automation MagneMotion,” said Studer. “MagneMotion is the only technology on the market that can do what we need it to do. It’s the only one that has the intelligence and the flexibility.”

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A customized solution

To meet KNEUSS Güggeli’s requirements, Stöcklin decided to design and build an entirely new system, centered around the MagneMotion solution. Based on patented linear synchronous motor (LSM) technology, MagneMotion offers an industry-leading combination of speed, precision, intelligence, configurability, and safety. 

Working with Rockwell Automation material-handling specialists, Stöcklin created a two-level sorting and processing system with three entry points. At each entry point is a barcode reader. This reads the label on a piece of packing and directs that package to the right customer crate.

These crates sit on one of 35 crate-holders. The system doesn’t use chains, belts, or gears — making it much safer than traditional sorting systems. Instead, each tray is moved independently along guiderails, using a system of magnets. 

Unlike a traditional conveyor belt, it’s easy to design turns into this system. So, you can save space without sacrificing flexibility or precision. And because it’s a two-level system, it uses less space than the machines it replaced, even though — thanks to the flexibility of the conveying system — it does more work, faster. 

The intelligent sorting systems know, based on the labelling, to which crate to route any tray. At a series of junctions — similar in concept to railway junctions, but without dangerous moving parts — the system sorts trays, sending each one to the right crate, where the system tips out the trays’ contents. 

Thanks to this advanced technology, the system can pack trays with much greater efficiency, making far better use of the available space. This reduces the quantity of trays required. It also means the same amount of product can be transported in fewer vehicles, helping to cut labor and energy costs, as well as emissions, associated with logistics.

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Labor productivity up by 15%

Thanks to its flexible design, the new sorting and packaging system occupies less space than the one it replaced. It also cuts down on the space required for pre-processing and storage. The company is free to use this space for new production and other work related to its plans.

The intelligent, automated routing function has enabled the company to increase labor productivity in its sorting and packing workflow by around 15%. The new system is also capable of processing 60% more packages in an hour, helping KNEUSS Güggeli fulfil more orders, on a faster turnaround.

“We’re extremely happy with the new system,” said CEO Daniel Kneuss. “It helps us be more efficient, safer, and faster to fulfil our customers’ orders. Working with Stöcklin and Rockwell Automation has been a great experience.”

And that isn’t the end of the story. Having created a brand-new, bespoke system based on MagneMotion, Stöcklin now plans to adapt and market the product for other customers, in a range of sectors. “MagneMotion is highly adaptable and configurable,” said Studer. “We expect to see high demand and uptake in many different types of businesses.”

Find out more about the potential of MagneMotion here.

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Published August 10, 2023

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