Dan Cake Polonia, a leading producer of baked goods in Poland, has successfully expanded its operations with the construction of a state-of-the-art logistics center in Chrzanów. Acting as the general contractor, Kardex Mlog has built a high-performance, fully automated high-bay warehouse equipped with advanced conveying and control technology to ensure efficient and secure processes. Despite the challenges posed by the global pandemic, the project was completed in 2022, marking a significant milestone for both Dan Cake Polonia and its Polish subsidiary.
Table of Contents:
- Background: The Scrumptious Delights of Dan Cake
- The Expansion of Dan Cake Polonia
- Construction of the Logistics Center
- Customized Service Concept for Sustainable Maintenance
- Overcoming Challenges during the Pandemic
- High-Performance Operations of the High-Bay Warehouse
- Streamlined Processes with the Kardex Control Center
- Efficient Shipping Operations
- Summary: Unlocking Expansion Potential for Dan Cake Polonia
- About Dan Cake
- About Kardex Mlog
1. Background: The Scrumptious Delights of Dan Cake
Sweet-smelling brownies, delicious muffins, and tasty pastry rolls – the Danish baked goods and cakes produced by Dan Cake have become symbols of the Scandinavian way of life.Founded in 1931 by Jens Eskildsen, the company has grown steadily and now offers over 350 different specialties on an industrial scale. With its international presence and production locations in Denmark, Germany, Poland, and Bangladesh, Dan Cake has established itself as a prominent brand in the bakery and confectionery industry.
2. The Expansion of Dan Cake Polonia
Dan Cake Polonia, a part of the Dan Cake Group since 2004, has emerged as one of the leading producers of packed bakery and confectionery products in Poland. With a modern production facility equipped with seven state-of-the-art production lines, the company supplies its own Dan Cake branded products and produces goods for major retail chains in the country.
3. Construction of the Logistics Center
In order to support its successful expansion, Dan Cake Polonia made the decision to construct its own logistics center in Chrzanów. Engaging the services of Kardex Mlog, a renowned consulting and planning company, in December 2019, a fully automated, high-bay pallet warehouse was constructed. With a budget of approximately 4.3 million euros, the project included extensive conveying technology connecting the manual picking area, production facility, and staging area in goods issue, as well as a newly built shipping hall. The modular Kardex Control Center ensures error-free operation with optimal ergonomics, while also allowing for future expansion.
4. Customized Service Concept for Sustainable Maintenance
The logistics center offers 6,400 storage spaces for pallets, with heights of up to 2.55m and double-deep storage. In addition to the construction and installation of the steel racking system, Kardex Mlog provided an extensive service concept for the maintenance and servicing of the entire plant. Leveraging the technical expertise of the Dan Cake employees, the coordination role was also handled by Kardex Mlog, ensuring smooth collaboration with other trades involved in the project.
5. Overcoming Challenges during the Pandemic
The construction of the logistics center faced multiple challenges, including the impact of the global corona pandemic. Starting in early 2020, the project experienced delays due to sourcing difficulties and restrictions on accessing the construction site. However, through a trusting and pragmatic collaboration between the project team from Dan Cake Polonia and Kardex Mlog, the project successfully progressed and was ultimately completed in mid-2022.
6. High-Performance Operations of the High-Bay Warehouse
The high-bay warehouse operates 24 hours a day, 7 days a week, and is run by three stacker cranes from Kardex Mlog. These advanced machines, with a height of approximately 30.3 meters and a payload capacity of 1,000 kilograms per load unit, ensure efficient storage and retrieval operations. Equipped with telescopic forks for double-deep storage, the stacker cranes can achieve up to 60 single cycles per hour. State-of-the-art controls and visualization software provide real-time monitoring and control of the warehouse operations.
7. Streamlined Processes with the Kardex Control Center
The Kardex Control Center, with the Kardex WMS management system, plays a crucial role in ensuring smooth warehouse organization. It receives orders from the host system and orchestrates the material flow, assigning destinations for each load unit based on order management and route planning. With the Kardex MVisu plant visualization system, operators have a clear graphical overview of the positions of the stacker cranes and conveying technology, enhancing operational efficiency and ergonomics.
8. Efficient Shipping Operations
The shipping station within the logistics center is equipped with 24 roller conveyors, enabling seamless transportation of pallets to distribution vehicles. With automated transport orders generated by the Kardex Control Center, the stacker cranes and conveying systems work in harmony to transfer the load units to the shipping, picking, or production areas. This optimized workflow ensures accurate order fulfillment and improves overall shipping efficiency.
9. Summary: Unlocking Expansion Potential for Dan Cake Polonia
With the completion of the high-performance, high-bay warehouse in Chrzanów, Dan Cake Polonia has gained significant logistics capacity for further growth. The collaboration between Dan Cake Polonia and Kardex Mlog has resulted in an advanced facility that ensures secure processes, efficient operations, and the potential for future expansion. The modernized plant with streamlined workflows positions Dan Cake Polonia for continued success in the bakery and confectionery market.
10. About Dan Cake
Dan Cake, founded in 1931 by Jens Eskildsen, is a renowned brand specializing in the production of bakery and confectionery products. The company offers a wide range of delectable treats, including brownies, muffins, and pastry rolls. With a history of ownership changes, Dan Cake returned to the Eskildsen family in 2004. For more information, visit www.dancake.dk.
11. About Kardex Mlog
Kardex Mlog, a leading provider of integrated material flow systems and high-bay warehouses, offers comprehensive solutions for efficient logistics operations. With over 55 years of experience, the company specializes in planning, implementing, and maintaining fully automated logistics solutions. Kardex Mlog’s expertise spans greenfield installations, refurbishments, and after-sales services. As part of the Kardex Group, the company employs 305 professionals and achieved revenues of €89 million in 2021. For more information, visit www.kardex.com
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