FreeBee A/S creates a safer working environment with Toyota’s semi-automated warehouse solution
Toyota’s Radioshuttle system has given warehouse operators at FreeBee greater peace of mind, improved overview and less day-to-day stress, while also laying the foundation for a more efficient and future-proof operation.
About Freebee A/S
Founded in 2006 and based in Nyborg, Denmark, Freebee A/S process and supply specialty chemicals and minerals to the primary and secondary aluminium industry, steel foundry, cement and abrasive sectors. Their modern manufacturing facility produces large volumes of tailor-made materials for customers in over 30 countries.
Facts & figures
- Company: FreeBee A/S
- Location: Nyborg, Denmark
- Industry: Raw chemical & mineral supplier
- Fleet solutions: Pallet stackers, electric forklifts, Cold store reach trucks, Toyota Radioshuttles
A warehouse under pressure, safety and efficiency at risk
At the manufacturing company FreeBee, the limitations of the warehouse located on the island of Funen began to affect daily operations. With increasing production volumes and more pallet movements, space scarcity became a real challenge.
“Previously, we stacked in pyramids and when the first bag was removed, it created an unsafe working area,” explains Henrik Rosenlund, Plant Manager at FreeBee, “It resulted in a lot of extra work, because we had to cordon off certain areas just to access the pallet we needed.”
This didn’t just affect efficiency; it also had consequences for the working environment. “Space equals safety: the less space you have, the more dangerous it becomes,” Henrik continues. The work of locating and retrieving pallets required additional lifting and created unsafe working conditions for employees.
A solution designed for the future
The need to optimise FreeBee’s logistics was clear, but management’s top priority was to create a safer everyday working environment. They found Toyota’s Radioshuttle system, with the possibility of full automation in the future, to be the best solution.
“The system we have now is significantly more efficient, both in terms of space utilisation and workflows,” says Jørgen Kildegaard, Managing Director at FreeBee, “Automation and future-proofing our operations also played a role in the decision, but first and foremost it was about ensuring our employees’ safety.”
Henrik adds: “We were not looking for just any solution; we were looking for the best one. It’s not only about putting up racking, but about creating quality and safety that will last in the long run.”
Improving daily operations to support employee safety and productivity
On the warehouse floor, employees quickly noticed the difference. According to Erik Christensen, warehouse operator at FreeBee, everything just runs more smoothly:
“Before, I was worried that something might collapse. Now I can operate three radioshuttles at the same time while feeling completely safe. I get much more done in a day. We spend less time searching for and moving pallets.”
He also highlights how the changes have had a positive impact on operators’ wellbeing. “There’s a more relaxed mood. People seem less stressed, because they have things under control.”
The improved workflows have also created a more consistent rhythm throughout the day with fewer unnecessary interruptions. This has made it easier to stay focused and has reduced the physical strain on employees.
Implementation with attention to detail
From the very beginning of the project, the focus was on tailoring a solution to fit FreeBee’s daily operations and workflows.
“We don’t deliver standard solutions,” Hanne Lützen-Laursen, Logistics Consultant at Toyota Material Handling Denmark, explains, “It’s important for us to adapt the solutions we offer to each customer’s specific needs. In the case of FreeBee, it has been a fantastic journey to be part of, because we can clearly see that we’ve made a real difference.”
Because each bag weighs approximately 1,500 kg, there were special load requirements. Henrik explains the high level of confidence FreeBee experienced throughout the process regarding this: “New calculations were made every time, even when the smallest changes were introduced. That gave us a very good feeling, knowing that everything was truly as it should be.”
The transition to the new system was seen as seamless by the employees. “I was surprised by how quickly I learned to use it,” says Erik, “We also got to know everything about the machines before they were fully put into operation and that gave us a good start.”
A workplace to be proud of
It’s not only the warehouse staff who feel the impact of the new system; management does too.
“I feel good when I drive home from work,” Henrik comments, “I have peace of mind, even when the night shift is on. I know everything is going to be alright.”
For Jørgen, the project also sends a clear message. “The safety of our employees means everything. This project shows both our employees and our customers that we take responsibility – something we consider extremely important.” He adds: “First and foremost, we did this for our employees. That’s the main reason for starting the project.”
A collaboration built on relationships
The collaboration between FreeBee and Toyota Material Handling is built on mutual trust and a long-standing relationship. “Toyota has been a supplier here from day one and the personal relationship has always been excellent,” says Jørgen.
For Hanne, it is precisely the relationship that makes the work meaningful: “It’s a fantastic feeling to go to work and help make a real difference for customers.” Jørgen adds: “We understand each other better when we’ve worked together over a long period of time. That means a lot.”
The solution at FreeBee allows for future expansion with AGVs, but the most important goal has already been achieved: safer working conditions for those who operate the warehouse every day.