Penske links bakery automation with a more resilient distribution model

Automation in food distribution is increasingly being judged by more than robot speed. The latest bakery project at Penske Logistics in Illinois combines robotic handling, software control and scalable storage to address several operational pressures at once: order accuracy, worker safety, labour availability and the need to deliver fresh products quickly.

The site previously depended on manual handling of bread trays. Employees unloaded, stored and picked stacks that could exceed two metres, creating demanding overhead work and opportunities for errors. The new system selects orders at tray level and assembles them automatically, with Penske reporting 100% order accuracy.

A connected operating architecture

Cimcorp’s MultiPick gantry robots work alongside an intelligent Warehouse Control System. Buffer storage and order picking are coordinated as one process rather than managed as disconnected steps. This creates a more predictable flow through the distribution operation and provides real-time information that can be used to identify and correct process constraints.

The operational implications extend beyond the warehouse. Faster order processing can reduce the interval between production and store delivery, supporting product freshness and remaining shelf life. Penske also expects labour requirements to decrease by 50%. That does not simply represent a headcount saving: it gives the operator scope to redeploy people to activities where human judgement and flexibility remain important.

Scalability as a resilience feature

The system’s modular design allows capacity to expand for demand peaks and longer-term growth. For industrial operators, that flexibility can be significant when volumes are variable and labour supply is uncertain. Automation also removes the need to manually manage tall tray stacks, improving the workplace conditions around a repetitive and physically demanding task.

Penske selected Cimcorp because of its experience with high-volume bakery applications. The supplier has delivered automation for Martin’s Famous Pastry Shoppe, Kwik Trip and Fazer Bakeries, as well as fresh-food customers including Alimerka, Mercadona, Netto and REWE. The project illustrates a practical Industry 5.0 principle: technology can standardise material flow while allowing employees to be used more strategically. Further information is available from Cimcorp and Penske Logistics.