Penske bakery robots remove need to handle seven-foot tray stacks

Penske Logistics has put a Cimcorp automated bakery order fulfillment system into operation, replacing manual tray handling with robotic storage and picking. Cimcorp says the system has reduced labor requirements by 50% and achieved 100% order accuracy.

The installation handles fresh bread and buns for Penske’s bakery customers. It combines Cimcorp’s MultiPick robotic technology with warehouse control software to manage product movement, hold trays until they are needed and assemble orders.

Previously, workers unloaded, stored, and picked bread trays by hand, handling stacks that exceeded seven feet in height. The new system selects and assembles all orders at the tray level, removing the need for manual overhead picking.

Cimcorp said the system is operating but did not identify the facility’s location, the bakery customers involved or the installation cost. It also did not provide daily processing figures or say how long the reported results had been measured.

Replacing seven-foot tray stacks

The previous process required employees to reach overhead to select trays from tall stacks. According to Cimcorp, this created ergonomic and safety risks and left room for picking mistakes.

The automated system combines temporary storage and order picking in one operation. Rather than having workers retrieve individual trays by hand, the equipment selects the trays needed for each order and assembles them for fulfillment.

Cimcorp says removing those repetitive tasks has cut labor requirements in half. The announcement does not specify whether that reduction reflects fewer positions, fewer hours, or employees moving to other duties.

“Automated systems like this one help Penske accelerate supply chain performance for its customers as these systems augment the capabilities of our highly trained workforce,” said Steve Chambers, Penske Logistics vice president of operations, distribution center management. “By implementing this system, we expect to see increased throughput efficiency and order picking accuracy as well as safety benefits from eliminating the manual handling of tray stacks.”

Faster handling for fresh bread

Cimcorp says faster order processing helps bakery products reach customers fresher and with more shelf life remaining. It did not disclose how much processing time the installation saves or quantify the shelf-life benefit.

The warehouse control software also provides real-time information about the operation. Cimcorp says that information can help teams track performance and identify opportunities to improve product movement and order handling.

Penske selected Cimcorp for its experience and technology in high-volume bakery operations. According to Cimcorp, the equipment’s modular design allows the operation to expand as demand increases, including during peak periods.

“Cimcorp’s experience and data-driven approach directly support our goal of continuously strengthening our customers’ supply chains,” Chambers said.