Back in 2008, Kardex Mlog had already built an automated high-bay warehouse for Moers Frischeprodukte. Now, due to ever-increasing demand, it had to be expanded again. This included another 44-meter- high high-bay warehouse with more than 17,000 pallet spaces, as well as a picking and shipping center. And that's not all.
Joint venture in Moers
Moers Frischeprodukte is a joint venture between the food company Dr. Oetker and the dairy Gropper. The Moers plant was familiar territory for the intralogistics experts at Kardex Mlog, as they had already built the previous automated high-bay warehouse there 17 years earlier. In January 2023, Kardex Mlog was once again commissioned as the general contractor. One of the project goals was to standardize the automation technology in both the existing and the expanded facility in order to minimize future maintenance costs.
«MVisu» in the Control Center
The new building's scope of supply now includes a pallet conveyor system with 353 drives and six stacker cranes. The 44-meter-high machines are manufactured in-house by Kardex Mlog at their Neuenstadt site and enable storage and retrieval. The "MVisu" module from the Warehouse Management Control Center is used for system visualization. Gravity roller conveyors, eight fire doors with free-travel control, and six high-speed doors complete the scope of supply.
A look inside the Control Center
In addition to delivery, Kardex Mlog also handled the assembly and commissioning, including the pre-zones and platforms, as well as all necessary modifications. These included adjustments to the conveyor technology and integration within the existing system while operations continued uninterrupted. To this end, Kardex Mlog developed a conversion concept with a corresponding schedule for each individual construction phase. "By planning the sub-projects jointly with all parties involved, we reduced the coordination effort and conserved resources," explains Sven Pitz, Head of Modernization at Kardex Mlog . He adds that the project allowed "teams and expertise to be pooled and strategically deployed.
Harmonious overall system
Furthermore, Kardex Mlog was responsible for connecting the electric monorail system with its 36 vehicles. These, along with the steel racking for 17,076 pallets, the roof and wall cladding, and the warehouse management system with material flow computer, were supplied by other manufacturers . "The almost seamless coordination of all trades, the smooth integration of the individual components into a perfectly harmonious overall system, and the competent project support from Kardex Mlog impressed us," emphasizes project manager Michael Dube of Moers Frischprodukte.
Moers Frischeprodukte GmbH & Co. KG was founded in 2018 as a joint venture between the food company Dr. Oetker and the dairy Gropper. Its purpose is to consolidate joint production in Moers. The focus of the joint Gropper and Oetker site is on the further development of the dessert product category, as well as the development of new opportunities in the areas of quark and yogurt, and dairy and non-dairy beverages.
Climate project at milk suppliers. Photo: Moers Fresh Products
On the topic of sustainability: In Moers, a "Climate Farms" project will evaluate how milk can be produced in a more climate-friendly way over the next three years. At six supplier farms, corresponding measures will be tested, and their feasibility, costs, and impact on climate and animal welfare will be assessed. Potential areas for improvement include feeding, feed production, animal husbandry, and the rearing of young cattle. Energy consumption and nutrient management also play an important role.
Numerous adjustment screws
Dr. Oetker is one of the leading branded goods companies in the German food industry. The family-owned company was founded over 125 years ago in Bielefeld. Its diverse product range includes approximately 1,000 products in Germany and around 4,000 different products worldwide. The Gropper dairy was founded in 1929 in Berg near Donauwörth. Its headquarters have been located in Bissingen since 1973.
