Sofidel warehouse project

Sofidel, one of the world’s leading manufacturers of tissue paper, is significantly expanding its production and logistics capacity at its Duluth, USA, facility. With an investment exceeding $200 million, the company is undertaking a comprehensive expansion project that includes modernizing its existing infrastructure and constructing a state-of-the-art automated warehouse. BT-Systems, leveraging its Competence Center ECE-LOG is executing a key project phase valued in the mid-eight-figure range. After a successful collaboration in Poland in 2018, Sofidel is once again relying on BT-Systems’ expertise. “We are extremely satisfied with the quality and efficiency of our past collaboration,” says Maurizio Cammisa, Capital Projects Director - Converting at Sofidel. “To optimize our logistics processes, we depend on cutting-edge technologies and strong partnerships, and we have found that partner in BT-Systems.” The project is scheduled for completion in 2026.

Highly efficient intralogistics for Sofidel Duluth
The new warehouse in Duluth has space for around 35,000 storage locations and is equipped with five high-performance storage and retrieval machines and innovative double-mover shuttles.

One major challenge of this project is the long connection to the production line, in which large parent rolls are processed into rolled and folded tissue paper and then packaged. Comprehensive conveyor technology line ensures a fast, safe and efficient material flow that fulfils the highest logistical requirements.

Maximum space utilisation in the warehouse
By using multi-deep racking with up to six pallets per storage channel, ECE-LOG enables particularly space-saving storage. Reducing the need for aisles maximises storage density and significantly increases space utilisation.

„We are extremely satisfied with the quality and efficiency of the collaboration so far."  
 

Maurizio Cammisa 
Capital Projects Director – Converting Sofidel

Energy efficiency through intelligent transport system
The warehouse uses an innovative, energy-efficient transport system that significantly increases transport performance and efficiency: The mover can move two pallets of up to 750 kg of tissue paper at the same time, doubling the transport capacity and reducing energy consumption. Thanks to this technology, material transport is not only faster, but also saves space and resources.

The combination of a reduced number of aisles, optimised warehouse structure and intelligent conveyor technology maximises the warehouse's performance and significantly reduces operating costs.

BT-Systems as general contractor
ECE-LOG, the Competence Center for warehouse systems and intra-logistics within BT-Systems GmbH, acts as general contractor and is responsible for the entire implementation - from planning to completion. The range of services includes rack construction, roof and façade construction, fire protection with sprinkler systems and all material flow systems inside and outside the warehouse. ECE-LOG also supplies the complete warehouse management software and the subordinate PLC control system. An additional advantage for Sofidel: The BT-Systems REDWAVE Competence Center with a branch in Atlanta guarantees direct and fast local service for American customers.

Review: Successful collaboration in Poland since 2018
Back in 2018, Sofidel relied on ECE-LOG's expertise and had a state-of-the-art warehouse with 32,000 storage spaces built in Poland. The system utilises innovative oxygen reduction technology that effectively prevents fires and reliably protects the stored products.

Another highlight was the fully automated AGV lorry, which has been handling in-house transport between production and the warehouse since 2021. This sustainable, electrically powered solution shows how ECE-LOG develops customised technologies to significantly increase the efficiency and safety of logistics.

Innovation as a success factor
With the second major order from Sofidel, ECE-LOG is once again demonstrating its leading role in the design of pioneering logistics solutions. "We are delighted that Sofidel has chosen us again - a special honour that makes us proud and motivates us. This order confirms that our customised and sustainable logistics solutions not only meet the high demands of a global market, but also create real added value," Thomas Lafer, authorised signatory and head of the ECE-LOG Competence Center emphasises.

Gerald Kreiner, CEO of BT-Systems GmbH, adds: "We are delighted to have been awarded this contract and to be able to utilise the synergies of the company merger to form BT-Systems in the implementation of this project. Two of our Competence Centers work closely with Sofidel: ECE-LOG benefits from REDWAVE's strong presence in the USA and can act quickly and in close proximity to its customers thanks to its branch in Atlanta, Georgia. Four Competence Centers under one roof offer our customers clear advantages and promotes innovative solutions at the highest level."

By realising the project in Duluth, Sofidel and BT-Systems are demonstrating their role as pioneers in the industry and shaping the future of logistics with pioneering standards for sustainability and efficiency.