Guylian creates a scalable warehouse for the future with Swarm Automation
Guylian employs approximately 200 people in Sint-Niklaas, where all their chocolate is produced. Master Chocolatiers produce up to 75 tons per day in a production unit of 27,000m². For internal material handling, they use around twenty different types of machinery, such as forklifts, reach trucks, manual pallet trucks with scissor lifts, stackers and AGVs. What began in the early 1990s as a straightforward supplier relationship gradually transformed into a strategic partnership built on trust, continuity and a shared commitment to quality. Guylian started automating production processes as some warehouse tasks were highly repetitive. That way their staff could be assigned to tasks with higher added value.
About Guylian
Guylian is a Belgian chocolate brand with a strong international presence. Guylian is sold in over 100 countries including Europe, Asia, Australia and the USA. They are best known for their Original Seashells: marbled Belgian chocolate filled with smooth hazelnut praline. Alongside quality, Guylian are also strongly committed to sustainability. They use Fairtrade cocoa, 100% natural ingredients, recyclable packaging and no palm oil or soya.
Facts & figures
Company: Guylian
Location: Sint-Niklaas, Belgium
Industry: Food
Trucks: 2 automated stackers (AGVs), 21 hand pallet trucks, 5 electric pallet trucks, 3 reach trucks, 3 electric pallet stackers, 3 electric forklifts
Fleet solutions: Swarm Automation
The evolution of trust: moving from manual to automated material flow
Before automation, Guylian’s warehouse operated much like many traditional manual environments. Skilled employees managed materials based on experience and intuition, often placing extra raw materials at production lines to avoid shortages. The system worked, but it relied heavily on individual judgement and the daily flow of goods could be unpredictable.
When Guylian decided to introduce AGVs (in 2017), the transition felt like a natural next step. The main objective was therefore not simply to automate tasks, but to create a more stable, structured and predictable process. “We have been working with Toyota Material Handling since 1990 and this 30+ year journey has been extremely positive,” says Liesbeth Coppens, Senior Communication Manager at Guylian, “We have grown together, evolving from manual forklift operations to a fully integrated automated logistics environment.”
The introduction marked a turning point. Processes that had once depended on personal habits became standardised, lean and fully aligned with ISO norms. Material now arrives at the right place, in the right quantity, at precisely the right time.
The AGVs ensure that only the correct pallet is delivered to each station, eliminating the risk of mix-ups and reducing unnecessary stock at the lines. With real-time data from the system, Guylian can manage inventory far more effectively, maintaining cleaner, more organised warehouse spaces and improving overall operational flow.
Safer operations, a more sustainable business
Today, two automated stackers operate seamlessly within Guylian’s logistics environment. They supply production lines, manage warehouse replenishment, and even handle the loading process without human intervention. Warehouse employees now work alongside the AGVs. Although the shift required some adaptation, the collaboration between people and AGVs has become smooth and intuitive. The result is a safer, more efficient workplace.
Swarm Automation brings together people, AGVs and software into a single connected system. The communication software acts as the central coordinator, ensuring that all elements work together smoothly and without errors.
“Swarm Automation has proven to be a reliable solution,” explains Noël Van der Gucht, Warehouse Manager at Guylian, “allowing us to reduce errors, create a safer workplace, and free up employees for more value-adding tasks.”
Previously, aisles could become cluttered, and the constant movement of manual forklifts created risks. By standardising workflows, the AGVs operate with maximum efficiency. The result is a warehouse environment that became more open, structured and easy to manage. The AGVs follow programmed routes with absolute consistency, avoiding damage to pallets and eliminating operational errors. This reliability not only enhances safety but also supports Guylian’s sustainability goals by reducing waste and preventing product damage.
Innovation through partnership: a shared journey of growth and automation
Teamwork is the engine to the success of the Guylian project. The automation journey moves in clear, manageable steps, each with realistic deadlines. Every project begins with detailed discussions, mapping routes, defining stations, and shaping a system that fits seamlessly into the customer’s workflow. It’s not just collaboration, it’s co-transformation.
Much of the design and simulation work happens off-site, so by the time the vehicles arrive, the installation phase runs smooth and effortless. Safety checks, route verification, and acceptance testing ensure that the system is ready for daily operations from day one. Operator training gives the team immediate ownership, while ongoing aftercare ensures continuous improvement.
One of the aspects Guylian values most is the quality of service. If maintenance is needed, a technician is on-site by the next day at the latest. The full-service contract and Sigma certification provide peace of mind, ensuring that the system is always supported, maintained and ready for future upgrades.
Scalable foundation for the future
In a food production environment with strict safety norms, understanding the full process and involving the people who work in it every day is essential. Today, Guylian’s warehouse is safer, cleaner, more predictable and more efficient than ever before. By introducing Swarm Automation, Guylian transformed good procedures into consistent daily practices.
In line with Toyota’s kaizen philosophy, Swarm Automation can expand gradually in both volume and complexity. Should the need arise to increase the AGV fleet or automate additional processes, the choice is straightforward: Swarm Automation hasn’t just optimised operations, it has empowered people, enhanced safety and created a scalable foundation for the future. The partnership that began more than three decades ago continues.