DESIGN ¦ DEVELOP ¦ DELIVER DESIGN ¦ DEVELOP ¦ DELIVERCASE STUDY | MAI DUBAI

EXPANSION IN THE AGE OF FULL AUTOMATION AND BIG DATATaste is just one of the many criteria that motivate customers in supermarkets, bars, restaurants, and hotels to buy bottled water. A balanced mix of minerals is yet another strong selling point — as is the purity of the water. Today, producers in search of success in international markets do well by implementing the highest quality standards in production and bottling.

The exponential growth of bottled water producer Mai Dubai LLC since its establishment in December 2012 is an excellent example of an inspiring success story in the industry. Since 2013, the subsidiary of the Dubai Electricity and Water Authority (DEWA) has been investing

in state-of-the-art technologies for its facilities to guarantee the production of high-quality end products. Due to its commitment to excellence, the young company has early on earned the region’s highest award for food safety.

Mai Dubai now enjoys an excellent reputation beyond the borders of the United Arab Emirates (UAE). Apart from being the official bottled water partner of Emirates Airlines, the company’s distinctive water bottles with the red lettering have also become a fixture in 13 countries across Asia, Europe, and Africa.

CASE STUDY

MAI DUBAIDUBAI, UAE

“Swisslog’s many years of

experience and expertise in logistics

automation for the food and

beverage industry convinced us to

go with Swisslog Middle East as

our intralogistics partner for our

expansion project.”

Alexander van 't RietCEO of Mai Dubai LLC

HIGHEST FOOD SAFETY STANDARDS

Key to the material and goods flow concept is the over 1,000-meter monorail system, which guarantees process-optimized transports – from receiving to the high-bay warehouses to production and the shipping area.

CASE STUDY | MAI DUBAI2

To meet the steadily climbing demand, the company decided in 2016 to further expand production by 2020. Mai Dubai has made massive investments in production and intralogistics and elected to rely on the expertise of Swisslog, to deliver its needs and requirements in this regard.

As part of an order valued over USD 20 million, Swisslog planned and implemented a fully automated intralogistics system based on intelligent software in the context of big data and Industry 4.0. The major expansion project included planning and implementing a new six-aisle automated high-bay warehouse for raw materials and packaging materials. A few hundred meters away, another high-bay warehouse was erected with 17,560 pallet locations for finished goods.

Swisslog Vectura stacker cranes, which are connected to the transport system, will provide swift and efficient storage and

retrieval processes in both warehouses. Key to the material and goods flow concept is the over 1,000-meter long monorail system, which guarantees process-optimized transports - from receiving the raw products and packaging materials warehouse to the production lines, the finished goods warehouse, and the shipping lanes in the distribution center.

Within the configuration a total of 44 Swisslog trolleys, each capable to carry two pallets at the time, can travel along the rail system.

In addition to the installation of warehouse technology components, the mega expansion project implemented by Swisslog also includes advanced high-performance information technology (IT) infrastructure and control technology. The ProMove pallet conveyor system from ensures the efficient flow of goods and sequencing of pallets in receiving and shipping. The Swisslog Warehouse Management Software is

DESIGN ¦ DEVELOP ¦ DELIVER

“Our target process optimizations are an important prerequisite to

remain competitive in the market today and over the long term. For intralogistics, Swisslog will prove

crucial to achieve this.”

Alexander van 't RietCEO of Mai Dubai LLC

crucial to this process. Algorithms guide the movement of goods across two floors to the right locations at the right time.

The modular software platform also offers a number of big-data business intelligence tools that can be flexibly added over time. With its modular architecture and its intelligent, automation-friendly design, the software helps Mai Dubai to prepare for the changes that Industry 4.0 brings so the company can benefit from the opportunities it offers.

SWIFT AND EFFICIENT PROCESSES IN TWO HIGH-BAY WAREHOUSES

HIGH-PERFORMANCE IT INFRASTRUCTURE

READY FOR INDUSTRY 4.0

DESIGN ¦ DEVELOP ¦ DELIVER

Both high-bay warehouses are equipped with Swisslog‘s Vectura pallet stacker cranes, ensuring high-quality processes, reliability, and less maintenance thanks to standardized processes and modules.

With its fl exible design concept, Swisslog’s ProMove pallet conveyor can be confi gured to meet specifi c customer requirements for pallet transportation.

3CASE STUDY | MAI DUBAI

Raw materials receiving area

Raw materials warehouse ▪ 14 meter height▪ 6 Vectura stacker cranes▪ 5,590 pallet locations

Monorail system▪ 1 km, 44 trolleys, 2 pallets per trolley▪ Linking FG WH with production lines

& shipping area▪ Linking RM WH with new & old

production lines

2

1

3

Software▪ Swisslog WMS (WM 6)▪ Vectura crane controls system▪ ProMove conveyor controls system

4

5

Production lines – old building

Production lines – new building

Finished goods warehouse▪ 26 meter height▪ 10 Vectura stacker cranes▪ 17,560 pallet locations

Picking (1st fl oor) & shipping (ground fl oor)

6

7

6

7

35

3

2

1

4

DESIGN ¦ DEVELOP ¦ DELIVER

One of the biggest expansion projects in the beverage sector in the UAE: The high bay warehouse buildings in the construction phase.

Swisslogwww.swisslog.com

BENEFITS ▪ Complete solution for end-to-end material flow: from receiving into the high-bay warehouse for raw and packaging materials to the production lines and from there to the high-bay warehouse for finished goods and to the shipping lanes in distribution.

▪ Requisite logistics in place to handle considerable increases in capacity in the coming years.

▪ Significantly improved efficiency in the flow of goods through automation and the use of state-of- the-art warehouse technology components.

▪ Perfect control of all logistics components through powerful software that is flexibly expandable.

SWISSLOG SERVICE ▪ Complete system design, engineering, simulation, implementation, and integration of two high-bay warehouses with associated monorail and conveyor technology.

▪ Warehouse management software and material flow control, flexible and expandable for Industry 4.0 applications.

▪ Facility visualization, user training, after-sales service.

FACTS AND FIGURES AT A GLANCE

Height 27 m

Number of pallet storage locations 17,560

Number of Vectura stacker cranes 10

High-bay warehouse for finished goods

Height 14 m

Number of pallet storage locations 5,590

Number of stacker cranes 6

High-bay warehouse for production and packaging materials

Number of trolleys 44

Number of pallets per trolley 2

Length 1,000 m

Monorail system

WMS/control

Swisslog software platform

Swisslog material flow controller

Swisslog control technology