When advanced technology, operational flexibility, and strategic partnerships align, they drive an intralogistics transformation that redefines the standards in terms of industrial efficiency, sustainability, and safety. This is exemplified by the partnership between Immergut and E80 Group — an automation project that fully embraces the principles of the Industry 4.0 paradigm.
“Thanks to the digitization of our lines and the elimination of format changeover times, we’ve achieved an average OEE (Overall Equipment Effectiveness) improvement of 3% and a considerable reduction in costs. Process optimization has increased shipping capacity by 60% — from 5 to 7/8 trucks per shift — greatly improving flow and delivering an ROI in under four years,” said Dirk Denhard, Plant Manager at Immergut.
Boasting over 125 years of history, the German company stands as a leader in the dairy industry. From its headquarters in Schlüchtern, it processes 74 million kilograms of milk, juices, and plant-based alternatives annually, using over 3,000 raw materials. With a well-established presence in Germany and consistent growth across Europe and beyond, Immergut remains a benchmark in its sector.
A MODULAR APPROACH FOR TOTAL FLEXIBILITY
The partnership with E80 Group was established with a clear and ambitious objective: to create a smart, fully integrated, and scalable ecosystem capable of supporting Immergut’s growth, streamlining its processes, and adapting effectively to market changes.
In collaboration with Tetra Pak®, Immergut selected the Group’s solutions for their high degree of flexibility and modularity, as well as their seamless integration with the existing processes. The project was structured according to a phased, brownfield approach, replacing several existing end-of-line systems with new solutions and enhanced functions, ensuring plant operations continued smoothly while meeting the customer’s specific production and distribution requirements.
“With our comprehensive portfolio of tailored solutions, we optimized Immergut’s entire production process, from palletization to automated pallet transport using Shuttles and LGVs. Despite space constraints, we successfully introduced a centralized robotic system for the automatic application of corner protectors, seamlessly integrated with our Silkworm wrapping machine. Downstream the wrapping system, we implemented the centralized labeling and an empty pallet feeding system, guaranteeing both efficiency and uninterrupted operations,” said Nicola Magrone, Sales Director DACH at E80 Group.
One pivotal aspect of this transformation was the virtualization of the production plant, made possible through 3D mapping technology. This tool enabled the creation of a highly detailed digital model of the facility, incorporating all operational elements — from LGV routes to the interconnections between the various automation zones. Thanks to this digitized environment, E80 Group was able to develop and test the systems virtually prior to implementing them. This offered a clear and accurate spatial overview from the outset, allowing potential issues to be identified early on and installation times to be streamlined. This approach proved essential for achieving precision, efficiency, and operational continuity within the Immergut plant.
AUTOMATION AND TRACEABILITY: FROM PRODUCTION TO SHIPPING
The system integrates Tetra Pak® lines directly with the truck loading area, ensuring complete traceability for every handled product. Immergut is now able to monitor its product flow in real-time — from packaging to shipping — for an unprecedented level of control.
The connection between the end of the line and truck loading is managed by Laser Guided Vehicles (LGVs), which operate autonomously and meet high safety standards. These vehicles transport pallets of finished goods throughout the plant, optimizing routes and reducing the likelihood of errors. By linking all the operations within the production and distribution facilities, the automated guided vehicles deliver the right products to the right locations at the right times. In addition to boosting productivity, the use of LGVs also enables more fluid and synchronized logistics operations. The versatility offered by this solution also allows for the creation of a temporary on-ground buffer for finished goods when truck loading is unavailable, ensuring continuity of production. This added capability enhances the system’s resilience and adaptability to distribution fluctuations.
At the heart of this achievement lies a strong, forward-thinking partnership built on mutual trust and a shared ambition: to create an increasingly automated, sustainable, and intelligent industrial future.
The Immergut case highlights how E80 Group’s integrated solutions not only improve efficiency and traceability but also adapt successfully to dynamic production environments, supporting companies on their paths to operational excellence.
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