Top Story

All fresh!

Using systems like the “Philadelphia line,” DB Schenker has upped the pace of its contract logistics on behalf of Mondelēz International. The global snacks company, which serves markets outside North America, was created in 2012, following the split from Kraft Foods. Seen in the portrait picture in the slideshow below: Site Manager Ingo Beckmann (left) and Head of Logistics Nicolas Kleindienst

Videos and photos: DB Schenker, Florian Oertel, Martin Schneider-Lau


Eight foil-wrapped packages to each little wooden box: that is how the first batches of Philadelphia from Bad Fallingbostel arrived on the market in 1961. In 2018, the cream cheese brand is proving more popular than ever. The plant in the North German district town is still one of the places where Philadelphia is produced – although nowadays in numerous and ever-changing varieties. Ensuring that the cream cheese, as well as several other products, are delivered quickly and in cartons containing the correct mix of varieties to customers throughout Europe and beyond falls under the remit of DB Schenker as the contract logistics provider for the manufacturer Mondelēz International.

 

The little wooden boxes of the past have long since been replaced by state-of-the-art technology and an ever greater degree of automation in the warehouse. “Our ‘Philadelphia production line’ has been in operation since mid-2016,” says Nicolas Kleindienst, who as Head of Logistics oversees the operations in the facility directly adjacent to the plant. The starting point of the production line is a machine that does nothing but continuously fold cardboard trays; and it ends with another machine that stacks two trays on top of one another and covers them with a carton lid.

In between these two machines, employees fill the trays with the plastic tubs in which the cream cheese is typically sold today. The filling process is completed according to the customers’ specifications, in general supermarket chains. “One supermarket might want a mix of yoghurt and full fat cream cheese on one tray, while another might want us to add Philadelphia Milka,” Kleindienst explains. “Thanks to the installation of the production line, which was realized as part of a continuous improvement project, the entire process is faster and more efficient.”


Order picking the mixed trays is handled in the co-packing section of the logistics center that measures well over 20,000 square meters. But this is only one link in a long chain of tasks. The locally produced tubs of Philadelphia cream cheese travel through a closed transport bridge leading from the neighboring plant to the warehouse via an electric suspension conveyor. Once there, the tubs are automatically stored in the high-bay warehouse in round-the-clock operations. This warehouse not only features well over 50,000 pallet spaces but is also equipped with recently updated electronic control systems.

Depending on the customer’s order, the cream cheese is then removed from storage. Some pallets are transported directly to the outgoing goods area, others go to order picking – and some end up on the “Philadelphia production line.” No matter what route the goods take through the warehouse, speed is always of the essence! “In the case of domestic deliveries, Mondelēz International transmits the order on the one day, and we ensure that it’s ready to be loaded by the next,” says Ingo Beckmann, DB Schenker Site Manager in Bad Fallingbostel.


“Although forecast figures allow us to adjust to the projected volume of goods required, we nevertheless have to deliver a top performance every time,” says Beckmann. The 170 employees at the warehouse also work flat out for numerous other brands produced by the manufacturer. “The ‘big players’ here include Miracle Whip, Oreo, Cadbury and Daim,” says Nicolas Kleindienst, Head of Logistics. While the salad dressing, called Miracel Whip in Germany, is also produced on site, other brands are transported to Bad Fallingbostel via truck from England, Sweden or Ukraine. Part of the Philadelphia cream cheese stock is also delivered here from one of the manufacturer’s plants in Spain.

 

Switzerland supplies a brand renowned for its distinctive triangular shape: Toblerone, which has rapidly taken on significant importance at the warehouse. “In early 2018, we began producing bags that contain three varieties of individually wrapped ‘Toblerone Tiny’ chocolate pieces and are sold mainly in airport duty free shops – an important business for Mondelēz International,” says Nicolas Kleindienst. This involves using a form, fill and seal machine that was specially designed and commissioned.

trucks on average leave the logistics center in Bad Fallingbostel every day. They carry a total of around 2,500 pallets that have been made ready for transport by DB Schenker. This figure includes around 500 pallets of commissioned goods


This colossus of a machine, which is several meters tall, transports the individual chocolate pieces along three ascending conveyors to a weigh station. These scales are programed precisely so that each large bag contains exactly 93 “Tinys” with a total weight of 744 grams. Simultaneously, the machine cuts the bags which are in fact stable pouches from a roll of film, molds them into shape and seals them. “At peak times,” says Kleindienst, who was responsible for implementing the system, “the machine can manage 55 bags per minute.” What is more, this machine also transfers the bags into cartons and then seals and labels them.

 

The examples showing how Toblerone and Philadelphia are handled here highlight the fact that the contract logistics processes which precede transport are growing ever more complex. As consumers’ tastes and preferences change, so do the varieties and packages available on the market. This requires intelligent solutions, of the kind demonstrated by DB Schenker in Bad Fallingbostel. Or as Ingo Beckmann says: “I think our warehouse is a pretty good indication of what we as a company are capable of achieving in the consumer goods sector.”

The plant belonging to Mondelēz International in Bad Fallingbostel is directly adjacent to the DB Schenker logistics center and both are linked by a bridge. The A7, one of Germany’s main traffic arteries, is only a stone’s throw away

Video: DB Schenker



Top Story

 

It’s all in the bag: Multiple sales channels, customizable products, strong seasonal fluctuations – Fossil’s leather goods business is demanding. That leaves plenty to do for DB Schenker, recently appointed contract logistics provider for the popular brand

> Read feature



Top Story

 

The platoon from DB Schenker, MAN and Hochschule Fresenius is underway! For the first time, digitally networked trucks are being deployed in real logistics operations. The three responsible partners address the key questions on a project designed to chart a new path for the future of land transportation

> Click to learn more



Top Story

 

Luxurious logistics: China loves Prada! More and more people in this vast country can actually afford to buy high-end goods from the luxury fashion house. Leaving plenty to do for the Italian brand’s exclusive logistics provider

> Read our feature



Top Story

 

The Olympic Winter Games in South Korea were an enormous event – for logistics experts, too. With its know-how and dense global network, DB Schenker ensured that athletes as well as journalists and sponsors from numerous countries are were perfectly equipped at the Games

> Read full story



Top Story

 

Kings of Queensland: Officeworks is Australia’s top retailer for office supplies and equipment. DB Schenker supports the company’s omnichannel strategy by handling ocean freight shipments, and especially with its sophisticated contract logistics

> Read our report



Top Story

 

The Mercedes-Benz V-Class is a winner in China! A version of the luxurious and spacious sedan adapted specifically to suit this gigantic market is manufactured locally by the Fujian Benz joint venture. Many of the components required are brought in by DB Schenker

> Learn more



Top Story

 

In the Sultanate of Oman, DB Schenker is handling a number of highly specialized assignments going well beyond the traditional realm of the Gulf region’s dominating oil and gas sectors. In addition, the team is promoting advancements in local logistics processes and standards

> Read our report



Top Story

 

The race between the races: At the Belgian Formula 1 Grand Prix DB Schenker worked flat out on behalf of Mercedes-AMG Petronas Motorsport

> Read full report and view a video clip



Top Story

 

Earwear hearing protection from Neuroth is music to the ears of young consumers who are increasingly going online to shop for goods. The Austrian manufacturer has turned to DB Schenker to provide the necessary e-commerce solution

> Learn more



Top Story

 

Warehouses on wheels: In the Finnish town of Uusikaupunki, Valmet Automotive produces cars on behalf of Mercedes-Benz, among others. Thanks to the contract manufacturer’s cooperation with DB Schenker the correct parts arrive at the production line right on time

> Click to read on



Top Story

 

Workplace Olympiastadion Berlin: The Bundesliga is one of the world’s strongest soccer leagues – and this season has seen Hertha BSC solidify its position! Prior to their home matches, the players rely on another team: DB Schenker handles logistics at Olympiastadion

> Take a look



Top Story

 

Made in Italy: the NGO Emergency provides the poorest of the poor with access to medical care. The supply of medicinal drugs and medical equipment is handled by the experts from DB Schenker in Milan – who also work on behalf of a host of other companies from the pharma and healthcare industries

> Read full story



Top Story

 

All-inclusive for robots: Kuka is one of the world’s leading manufacturers of industrial robots. DB Schenker provides the company with comprehensive support – from production supply to the distribution of finished robots 

> Read feature and view a video clip



Top Story

 

E-commerce: The online pharmacy Apotea.se has become firmly established in Sweden in record time. As a consummate entrepreneur, Pär Svärdson is fine-tuning the company to expand even further. DB Schenker is responsible for delivering several hundred thousand Apotea consignments to customers every year  

> Learn more



Top Story

 

Electric titans: Five converters weighing a total of 700 metric tons – a case for the heavy-duty experts at DBiSCHENKERspecial! Armed with a film camera, “logistics NewsFeed” was permitted to accompany the team on their mission in the German city of Frankfurt (Oder)  

> Read story and view our video