Grocery retail is characterized by high dynamics, increasing complexity of product ranges, and growing customer expectations with regard to delivery speed and availability, according to TGW Logistics. The integrator specializes in palletizing and warehouse automation.
TGW noted that high-performance systems are essential for efficiently processing large-volume material flows, especially in the field of full case handling. An intelligent software platform plays a central role here, particularly when it comes to palletizing.
“We are in constant contact with our customers. Intensive communication and the ideas that arise from it help us to stay on the cutting edge,” explained Michael Schedlbauer, vice president of business development of grocery at TGW Logistics.
The Marchtrenk, Austria-based company has more than 25 years of experience in the grocery industry. It offers intralogistics systems suited for cold-chain applications. Its full-case solutions cover all temperature zones—from dry goods to fresh and frozen foods (-22°F/-30°C).
TGW added that its systems enable automated handling of pallets, roll cages, and thermo-containers.
TGW takes a software-first approach to palletizing
At the center of every TGW Logistics installation is its software platform WERX. With its team of over 700 specialists, the company said it develops modular software for the control, optimization, and visualization of all material flows.
TGW said it places a special focus on palletizing. This system, with the help of intelligent algorithms, needs to deliver maximum packing density and optimal packaging stability. It can place more than 700 packing units per hour, with modular design, high redundancy, and optimal accessibility for maintenance.
The integrator said it constantly tests, calibrates, and develops its software further with the help of demonstration and test systems.
AI can boost efficiency, reduce manual intervention
For depalletizing, TGW Logistics relies on camera-based, self-learning system behavior. With the help of AI algorithms, the automated system can recognize patterns and analyze error patterns directly in the visualization.
This fuels a continuous learning process that reduces the amount of intervention required from operators by up to 30%, which in turn directly affects the system’s overall performance, TGW said.
An intelligent multi-layer approach also comes into play during the creation of the packing plan before palletizing. This allows multiple requirements to be considered simultaneously and to be activated or deactivated as needed.
In addition, TGW said its software can recognize any need for optimization based on current capacity utilization. This feature has already proven itself in practice for one of the leading food service providers in the U.S., the company claimed.
When it comes to supplying end customers, the duration of stops to unload customer deliveries can be drastically reduced, asserted TGW. This increases efficiency along the entire supply chain and strengthens competitiveness.
TGW touts security as an integral feature
Logistics providers are facing rising regulatory requirements. Examples include the NIS2 Directive for securing networks and information systems, as well as intralogistics as part of critical infrastructure under the German KRITIS regulations.
TGW said it is setting high standards in terms of security, availability, and data protection—both for customers and for its system landscape.
“We are making long-term investments in IT security and process reliability,” said Hans-Peter Dirisamer, director of group IT at TGW Logistics. “Our aspiration is to establish sophisticated security structures that will play a preventive role and enable swift reaction in case of emergency.”
“TGW Logistics takes a comprehensive approach that encompasses not only technical but also organizational measures,” he added. “This includes redundant system architecture, coordinated access regulations, data encryption, and continuous monitoring, as well as emergency plans and recovery scenarios whose effectiveness are tested regularly.”
Expansion to split-case picking: One system, two worlds
With the growth of online business, the requirements associated with picking single items for end customer orders — or split-case picking — are also on the rise.
TGW has has already implemented technology to address these requirements at multiple customer sites designed especially for e-commerce. They can now handle over 20,000 units per hour, and the company said its systems are suitable for delivering products directly to end customers directly or for supplying stores with small lot sizes.
Moreover, TGW offers integrated systems that combine full-case and split-case picking, allowing the same system to handle both fast-moving and slow-moving items.
TGW’s case picking offering includes:
- Highly dynamic shuttle technology to supply both areas at once; they also have trays to hold multiple SKUs for higher storage density and flexible picking
- An external sequencer developed in-house that sorts items intelligently based on delivery criteria and the target, such as for palletizing or further processes
- The patented PickCenter One, a 1:1 picking workstation with an integrated target sequencer for optimized picking order
This integration offers maximum flexibility in the face of changing business models, said TGW. It cited examples such as seasonal transitions, changes to the product range, or increasing affiliation with convenience stores.
The company also noted that it has experience in integrating and scaling software and automation into existing buildings. TGW said the modular design of its systems allows it to insert single functional units into existing infrastructure and processes with minimal disruption.