The Barry Callebaut Chocolate Box

A state-of-the-art high-bay warehouse, supporting the global operations of one of the world’s largest chocolate producers

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Delivering sweet success through automation

Barry Callebaut is one of the world's largest manufacturer of high-quality chocolate and cocoa products. With more than 12,000 employees in 63 factories worldwide, the group supplies chocolate to 143 countries. In 2018 Barry Callebaut finalised plans to build a large new warehouse, and tasked SSI SCHAEFER with one of the largest projects we have realised in Belgium. This site plays a critical role for the company, serving as a key hub from which millions of tons of chocolate are distributed globally.

The SSI SCHAEFER team began a close collaboration and set out plans to design a fully automated warehouse solution that would not only be optimally laid out, but also meet strict sustainability targets.
 

The Solution

After analysing the size and shape of this brand new footprint, we delivered a 124 × 100-meter, 40-meter-high clad-rack silo for Barry Callebaut, where the structure itself supports the walls and roof. Key features of this automated high-bay warehouse include:

• High bay warehouse double deep (115 x 96 x 40 m)
• 13 aisles with 13 SSI Exyz cranes, (83,000 pallet capacity)
• Pallet conveying system (PCS)
• Electric monorail system (EHB)
• WAMAS® Lighthouse
• Customer service: SSI resident maintenance

Together with our successful automated warehouse solution, the building ultimately received a BREEAM Outstanding certificate, and thus achieved the highest sustainability score for logistics buildings.

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Smooth operations thanks to the Resident Maintenance team

Together with Barry Callebaut, to keep this large system running we provide our very own Resident Maintenance Team (RM Team). The RM team provide carefully regimented maintenance activities In combination with further process optimisations. This allows for the chocolate to keep on flowing whilst allowing for maximum uptime.

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