V-ZUG Kühltechnik Sulgen Refrigerator Factory
⭐Key Features
- •Four-aisle high-bay warehouse with automated storage/retrieval machines
- •Automated guided vehicles (AGVs) for material transport
- •SRMs that change aisles autonomously
- •Entire conveyor system renewed in collaboration with GEBHARDT
- •Significant automation of the 100 audit area
- •Workplace ergonomics and digitalization investments
📊Results & Benefits
- ✓Production capacity of 145,000 refrigerators annually
- ✓One refrigerator produced every minute
- ✓Professional factory prepared for the future
- ✓Significant efficiency increase in factory operations
- ✓Flexible and quick response to market needs and new technologies
🎯Challenges & Solutions
Expired rental contract in Arbonne and aging facility no longer state-of-the-art
Built new factory in Sulgen with renewed conveyor systems and automation
Manual operation of storage/retrieval machines requiring dedicated personnel
Implemented automated four-aisle high-bay warehouse with autonomous SRMs
📝Project Overview
Project Overview
V-ZUG Kühltechnik AG, developer and manufacturer of refrigerators and part of the successful V-ZUG Group with origins dating back to 1913, faced the need for a new production facility due to an expiring rental contract in Arbonne and an aging building that was no longer state-of-the-art. The company, which has made innovative household appliances its business for over 100 years, decided to build a new production site for refrigerators of all heights and dimensions at the Swiss location Sulgen.
Only about one-fifth of all equipment and installations were transferred from Arbonne to Sulgen, with the majority of components, including the entire conveyor system, being renewed in collaboration with GEBHARDT. This represented a significant modernization opportunity to create a professional factory prepared for the future with advanced automation and logistics systems.
The project goals included improving productivity, efficiency, and sustainable profitability through automation investments, particularly focusing on workplace ergonomics and digitalization to enable flexible, quick responses to market needs and new technologies.
Technical Solution
Four-Aisle High-Bay Warehouse
The facility features a four-aisle high-bay warehouse with automated storage and retrieval machines (SRMs) that can change aisles autonomously. This represents a significant advancement from the previous manual operation where one person was required to drive pallets back and forth daily in the storage system.
Meyer Corporation USA Cookware Distribution Center
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Key Features
The four-aisle high-bay warehouse with autonomous SRMs that change aisles represents advanced automation compared to the previous manual operation, eliminating the need for dedicated personnel to operate storage and retrieval equipment.
The AGV system provides efficient material transport throughout the factory, contributing significantly to overall operational efficiency while supporting the high production volume targets.
The significant automation of the 100 audit area improves quality control efficiency while integrating with the overall production flow, supporting both speed and quality objectives in refrigerator manufacturing.
Results & Benefits
The factory achieves impressive production capacity of 145,000 refrigerators annually, equivalent to producing one refrigerator every minute. This high-volume capability supports V-ZUG's market position in the competitive appliance industry.
A professional factory prepared for the future has been created through investments in workplace ergonomics, automation, and digitalization, enabling flexible and quick responses to market needs and new technologies.
Significant efficiency increases have been realized throughout factory operations, particularly through the automation of material handling processes that previously required manual intervention and dedicated personnel.
Challenges & Solutions
The expired rental contract in Arbonne combined with an aging facility that was no longer state-of-the-art necessitated a new production site. The solution involved building a completely new factory in Sulgen with renewed conveyor systems and advanced automation from GEBHARDT.
The manual operation of storage and retrieval machines requiring dedicated personnel to drive pallets daily was addressed through the implementation of an automated four-aisle high-bay warehouse with autonomous SRMs that change aisles without human intervention.
System Integrator
GEBHARDT Intralogistics Group served as the system integrator, accompanying the development process from the first sketch to the overall production system and realizing two intralogistics systems for the new plant. V-ZUG selected GEBHARDT because their system is clean, efficient, and easy to operate, and they found a partner with whom they could develop a tailor-made concept specific to refrigerator manufacturing requirements.
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