ABB Automation Elevates Nespresso's Efficiency in Benelux

Nespresso, a well-established Swiss coffee enterprise cherished for its direct-to-consumer approach, has embraced automation to refine the delivery service for its Benelux clientele.

The brand's commitment to quality service amid growing demand necessitated an overhaul of its order-processing system, driving the adoption of a more accurate and efficient methodology.

Collaborating with logistics service provider ID Logistics (IDL), Nespresso has integrated a comprehensive automation solution developed by ABB.

This sophisticated setup, located at the IDL-operated distribution centre in Tilburg, Netherlands, encompasses advanced robotic depalletising, high-speed picking and precise order packing, all managed by intelligent software and supported by round-the-clock technical assistance.

“With Nespresso seeing continued growth in demand for its products, the company was keen to see how an automated order handling could help,” says Dominic Maas, Site Manager at IDL.

Previously, the manual process undertaken by IDL personnel for picking and packing coffee sleeve orders proved inadequate with the increase in order volumes.

Technological dynamics of ABB's system

ABB's sophisticated system operates in a dual-phase workflow: initiating with the depalletisation of coffee sleeve boxes, followed by meticulously picking individual sleeves to compose customer orders.

At the heart of this process is ABB's IRB660 robot, which efficiently handles the depalletising task by selecting appropriate boxes from a selection of 40 palette positions and transferring them onto a conveyor belt.

Subsequently, these boxes are automatically opened to reveal the coffee sleeves they contain.

The next phase is expertly managed by ABB’s FlexPicker IRB 360 robots.

This quartet of delta robots engage in high-speed picking, accessing a selection of 10 different coffee sleeve variants to perform up to 150 picks per minute.

Capable of collecting up to five sleeves simultaneously, they deftly position them into customer order carts travelling along a moving line.

The carts then proceed to a packing station, where an operator receives instructions on the appropriate box size.

Upon automatic insertion of coffee sleeves into the box, the operator supplements the order with any added items, such as chocolates, before sealing the box and attaching a label.

This entire process is orchestrated by ABB’s material management software, interfacing seamlessly with Nespresso’s warehouse management system.

It efficiently controls both the product and data flow, aided by a SCADA (Supervisory Control and Data Acquisition) system that visualises key performance indicators and compels real-time operational support.

“We chose the ABB system as it had the most innovative and convincing design to meet the project requirements,” Dominic adds.

Enhanced output and visibility

This state-of-the-art implementation produces a nimble operation that maintains Nespresso's hallmark quality even at increased scales.

It achieves this by automating checks and quickening order handling, bringing down the rate of customer complaints and rejections to a mere 0.06% of all orders.

The system's flexibility enables it to adapt to fluctuating order volumes without requiring packaging modifications, utilising existing boxes and pallets.

Operators benefit significantly from an intuitive user interface that identifies and suggests solutions for faults.

The robot interface provides visual activity maps, enhancing quick responses to minor disturbances.

“We have been delighted with the system, which is increasing our agility and our ability to fulfil customer orders more efficiently with less errors,” says Sorin Geambasu, Global Warehouse Efficiency Manager at Nespresso.

ABB's support extends beyond installation, offering IDL staff training for minor system adjustments and providing 24/7 remote and onsite technical assistance.

Potential for broader application

Inspired by the success at Tilburg, Nespresso and IDL are poised to consider the deployment of similar automation technologies at additional sites.

This pioneering application of automation stands as a model for boosting service levels and output efficiency, setting a precedent for future expansions.

“This is the first time that such an innovative automated solution has been implemented for Nespresso,” says Sorin.

“We are always reviewing ways to improve customer satisfaction and automation has proven itself as a way of achieving this.

“We are now looking at how we can implement this type of solution in other facilities to better serve our customers in the future.”