Automated warehouse supports food producer’s rapid growth
Project facts
- Client
- Peka Kroef
- Location
- Odiliapeel, North Brabant, The Netherlands
- Date
- 2024-2026
- Challenge
- Growing order volumes create the need for automated storage and picking system.
- Solution
- Fully automated warehouse designed for chilled environment and integrated with client’s production systems.
Peka Kroef is growing fast. To reliably meet customer demand, it needed to increase its storage and picking order capacity, previously serviced through an external warehouse and at other Peka locations. The company contracted Haskoning to design a new warehouse for its production site, identify the optimal automation solution, and ensure smooth integration with site systems and operations.
Data analysis and simulations guide concept
Data analysis determined storage and throughput needs as well as peak capacity to guide the concept. The solution was validated through simulations. These were repeated mid-way through the project after a steep jump in order volumes when a competitor ceased trading. The later simulation confirmed that capacity calculations continued to meet future demand.
Although Peka’s production operation is highly automated, warehousing and order picking was done manually. Part of Haskoning’s role was to identify the optimal level of automation in the new warehouse and ensure it could be successfully integrated with existing systems.
Haskoning’s supply chain team provided support during the tender phase, conducting reference visits with Peka to ensure the chosen solution met the required quality and specification.
We explored various automated and manual arrangements using simulations. The solution we chose replaces manual order picking with automated systems that deliver pallets to picking stations where operators are guided and assisted by vacuum lifts. This level of automation is typical in e-commerce solutions but less common in the food industry.
Multiple disciplines come together for a successful solution
“The project required close cooperation between building, supply chain and logistics teams, such as integrating fire safety systems and mezzanine design with mechanisation requirements,” said Joke. “Suitable materials were chosen to withstand the chilled, warehouse environment. Our client paid close attention to ensure the building design reflects the values of the company. It has large windows providing lots of natural light, and comfortable facilities for employees in the office area.”
With the building complete, Haskoning is providing support during installation, testing and post-implementation of the automation system. This coincides with introduction of a new warehouse management system and production execution system. There is close coordination with all the teams involved to ensure robust interfaces and connections between systems, as well as a smooth operational start up, scheduled for September 2026.
Sustainability and well-being embedded in the solution
Sustainability features include energy-saving initiatives, a comfortable work environment and reduced transport emissions. The building designed by Haskoning is based on a box-in-box principle; corridor zones surround the chilled warehouse to provide an extra layer of insulation. The building team introduced solar panels and energy reduction systems to offset the high energy use of chilled storage. Automation reduces manual handling and creates a healthier work environment for employees. By bringing logistics back in-house, the project significantly reduces truck movements to external warehouses, lowering CO2 emissions.
During implementation of phase one, the team was awarded the contract for phase two. This involves temporary storage for partially finished products and requires integration with production and packaging lines, as well as further logistics enhancements.
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Managing growth and increasing complexity in Food & Beverage operations? Together with our clients, we design and implement warehouse and automation solutions that are grounded in data and validated through simulations, and that integrate seamlessly with production systems, supporting efficient, reliable and future-ready operations.Solutions for industry
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