BevChain Australia Distribution Center

Project Overview

BevChain, a wholly owned subsidiary of Linfox and leading beverage logistics specialist across Australia and New Zealand, operates 22 distribution centers across six states handling more than 2.5 billion serving units annually. The company sought to transform performance and productivity in what was largely a traditional warehouse operation through advanced automation.

The project involved installing Australia's first high-density PowerStore system, designed to significantly increase storage capacity while creating a safer workplace and delivering growth for customers. The automation solution represents BevChain's commitment to working smarter for customers and investing in high-performing supply chains with best-in-class technology.

Swisslog served as the system integrator, delivering a comprehensive automation solution that includes intelligent software integration and ongoing operational support.

Technical Solution

PowerStore High-Density AS/RS

The facility features Australia's first PowerStore system with over 30,000 pallet locations distributed across five levels. The system utilizes vertical conveyors to transfer pallets between levels, maximizing vertical space utilization while maintaining the same building footprint.

Key Features

The PowerStore system's 30,000+ pallet locations across five levels represent a significant advancement in high-density storage technology for the Australian market. The vertical conveyor system enables efficient inter-level pallet transfer, while the satellite carriers provide precise material handling within each storage quadrant.

The intelligent Sync software integration creates a seamless connection between automation and warehouse management, enabling data-driven decision making and optimization. The roll-on roll-off dock design facilitates efficient interface with adjacent brewery operations, streamlining the supply chain for beverage customers.

Results & Benefits

The PowerStore system delivered a remarkable 60% increase in storage capacity within the same building footprint, dramatically improving space utilization. The automation significantly improved both inbound and outbound performance while reducing operational costs across the operation.

Workplace safety was enhanced through the automated handling systems, reducing manual pallet handling requirements. Order fulfillment accuracy and speed increased substantially, creating a smooth and controlled operational process that supports efficient 24/6 customer operations.

Challenges & Solutions

The primary challenge was transforming performance and productivity in what was largely a traditional warehouse environment, requiring a significant technological leap. The solution involved implementing Swisslog's next-generation PowerStore automation with a carefully planned staged go-live phase that minimized operational impact during commissioning.

The Swisslog and BevChain teams worked tirelessly to ensure a smooth and successful transition, with close collaboration throughout the implementation process. This partnership approach ensured the complex automation system was properly integrated and optimized for BevChain's specific operational requirements.

System Integrator

Swisslog provided comprehensive system integration services and maintains an integrated system operations team of experts who work closely with BevChain on-site. This team provides ongoing software support, training, condition monitoring, and spare parts maintenance to optimize the automation system's lifecycle.

The highly skilled onsite Swisslog team works in partnership with BevChain personnel, providing vital insights, immediate incident response, and proactive equipment monitoring to ensure maximum efficiency over the system's lifespan. Their extensive site knowledge ensures the operation runs at full capacity while enabling BevChain staff to gain new knowledge and skills in warehouse automation technology.