De'Longhi optimises their logistics flow with Swarm Automation
In Romania, De'Longhi operates an advanced logistics centre in Cluj County where it produces fully automatic coffee machines. As part of a major project to streamline production processes within the De’Longhi Group, Toyota Material Handling Romania was brought in to implement a system for transporting pallets from the production lines to the storage and delivery areas. Swarm Automation enables the efficient management of goods movement by streamlining De’Longhi’s processes and reducing manual intervention.
About De'Longhi
De’ Longhi was founded by the De'Longhi family in 1902. What started as a small industrial parts manufacturing workshop is now one of the world’s leading players in the household appliance sector, mainly active in the coffee and food preparation segments. Born in 1974 as a brand of electric radiators, De’ Longhi broadened its offer over time to every area of the house, adding brands like Kenwood (UK) and Braun (DE), among others, to its portfolio along the way.
Facts and figures
- Company: De'Longhi
- Location: Cluj County, Transylvania
- Industry: small household appliances, automatic coffee machines
- Solutions: 4 Toyota SAE160 Autopilot stackers
Pallet transport automation for (energy) efficiency and safety
In just eight weeks, the local team implemented an automated pallet transport system in the De'Longhi warehouse, comprising of four AGVs (automated guided vehicles), connected to the robotic arms’ control system, with Toyota's automation software, T-ONE, serving as an integration layer for smooth communication. The result: stable, safe and optimised interaction between Toyota AGVs and the automation already existing in De'Longhi plant. In addition to picking up the finished products from the palletising areas, the AGVs also ensure that they are supplied with empty pallets.
The Lithium-ion batteries eliminate the need for a separate charging room. The system features automatic battery charging, resulting in a fully automated system where no human interaction is required to change and charge the batteries. It supports an 8-hour continuous operating cycle, allowing the AGV to function uninterrupted for up to eight hours on a single charge. After depletion, the battery completes a full charging cycle in just 50 minutes, enabling rapid turnaround and minimal downtime.
Another important improvement is the existence of a continuous, uninterrupted workflow, 24 hours a day, in which employees benefit from a safer and visibly improved working environment. The AGVs are equipped with a 360° safety system that provides comprehensive visibility and protection from all angles, helping operators avoid collisions and maintain a safer working environment.
Operational benefits and impact on human resources
Automation offers numerous benefits that address both immediate operational challenges and long-term strategic goals. One of its most impactful advantages is its ability to cover labour shortages, especially in sectors where skilled workers are increasingly difficult to find. By automating repetitive and physically demanding tasks, businesses can maintain productivity without being disrupted by a lack of workforce.
“From the beginning,” explains Ovidiu Vîrlan, Automation Engineer at De’Longhi,
“we made the decision that the human resource should be redirected in various other processes that bring more value to our company,
eliminating the challenges faced by the Romanian labour market. All the benefits make us conclude that it is a profitable and necessary investment in the current context.”
Additionally, automation significantly reduces the risk of damaged goods during handling and transport, and minimises costly errors caused by inefficient handling, ensuring consistent quality. Its inherent predictability allows for streamlined workflows and accurate forecasting, which improves planning and decision-making.
The collaboration reflecting a perfect synergy
The collaboration between De'Longhi and Toyota Material Handling Romania reflects the perfect synergy between industrial tradition and cutting-edge logistics technologies. “This is a landmark project for Toyota Material Handling Romania that required the collaboration of all parties, and in De’Longhi we found a partner open to this challenge,” says Dragoș Oprea, Logistics Solutions Manager at Toyota Material Handling Romania.
“De'Longhi benefits not only from Toyota's know-how in handling and automation,” he adds, “but also from a systemic approach that amplifies the efficiency and flexibility of its warehouse operations.”
A return on investment guaranteed, within two to three years, this automation project is not just a technological upgrade but a financially sound strategy for De’Longhi’s sustainable growth.