In line with its long-term strategy to optimize the warehouse network structure, the Rewe Group is equipping its National Logistics Center in Neu-Isenburg with automation technology. The goal is faster, more efficient, and high-quality supply of goods to the Rewe markets. The order for implementing the fully automated Order Picking Machinery (OPM) system has been awarded by the retail group to the Witron Group.
“Rewe, together with Witron, delivered a masterpiece in the realization of the logistics center in Henstedt-Ulzburg,” explained Rewe logistics manager Lars Siebel. “And we want to repeat this success in Neu-Isenburg now.”
The new system replaces a partially automated case-picking procedure with aisle-bound vehicles with a comprehensive OPM solution. The integration takes place during ongoing operations into the existing material flow infrastructure.
"The advantage of OPM is that Rewe can ergonomically store and pick over 100 percent more case-picking items in the future, with an overall throughput of the site that is more than 20 percent higher. While the assortment in the previous solution included 3,000 different items, the OPM now includes 7,800 products. The pick performance increases to 247,500 picks per day," explains Witron Project Manager Markus Lang.
From the third quarter of 2027, the daily 247,500 trading units are to be stacked neatly and error-free on pallets and roll containers by 22 COM machines. Before that, the goods go through a tray warehouse with 167,900 storage spaces and 48 storage and retrieval machines. Supply is provided from an automatic pallet warehouse, which will be expanded by two additional aisles with a total of 9,500 storage spaces.
2,200 branches supplied with 16,700 items
From Neu-Isenburg, around 2,200 branches are supplied with 16,700 items from the dry goods assortment. On peak days, over 640,000 trading units need to be picked. The OPM technology also enables efficient consolidation with orders from existing Witron systems: the DPS (Dynamic Picking System), OPS (Order Picking System), and CPS (Car Picking System) for large-volume and bulky items. These systems have been in operation at the site since 2014 and 2021, respectively.
Witron is a "Lifetime Partner"
Witron is responsible as a so-called Lifetime Partner for the complete implementation of the project – from planning through realization to on-site service. All IT, PLC, and mechanical components come from the company headquarters in Parkstein. Additionally, Witron developed the transition strategy for continuous store delivery during the reconstruction measures and supported the selection of a specialized recycling partner for the dismantling of no longer needed technology.
Rewe Group on a Future Course
The modernization in Neu-Isenburg is part of an extensive future program by the Rewe Group. Despite a challenging environment, the company was able to increase external sales by 4.6 percent to 96 billion euros in 2024. EBITA remained stable at two billion euros. By 2028, Rewe plans investments amounting to 16 billion euros in digitalization, locations, and infrastructure. In 2024, 46,000 new employees were hired, including 5,000 trainees.
