The REWE Group is transforming the site within existing premises into a sustainable and innovative logistics hub, incorporating state-of-the-art warehouse technologies. From there, the company will supply its BILLA, BILLA PLUS, BIPA, and ADEG stores, as well as cooperation partners such as gas station shops, with dry goods. “This project is a milestone for our entire company group. With the new logistics centre, we are creating the infrastructure needed for modern, efficient, and sustainable retailing”, explains Peter Maly, REWE Group Board Member for Logistics and Supply Chain Management.

“In Wiener Neudorf, we are building one of Europe’s most modern retail logistics platforms – a sustainable and resilient backbone for our supply chain,” emphasizes Marcel Haraszti, Executive Board Member of REWE International AG. “We are consolidating our goods flows, reducing transport volumes, increasing supply reliability, and creating new jobs for highly qualified employees in logistics, technology, and IT.”

Efficient module mix with high cost-efficiency

The facility will utilize WITRON’s OPM (Order Picking Machinery) and CPS (Car Picking System) solutions, enabling fully automated, semi-automated, and store-friendly stacking of cases onto pallets and roll containers. A unique feature of the CPS solution is that employees pick items in a path-optimized manner – guided by a pick-by-voice system – from a pick front stocked with layer trays, totes, and pallets. Replenishment is handled by stacker cranes.

Small-volume items will be picked directly from storage totes into shipping totes at eight ergonomically designed workstations using the DPS solution and guided by pick-by-light technology. Here too, the pick front is permanently and automatically replenished by stacker cranes. The individual logistics areas are connected via a conveyor system network. An intelligent consolidation strategy ensures optimal load carrier utilization for stores, resulting in significant transport cost savings.

In total, the entire material flow includes almost 550,000 storage locations for pallets, trays, and totes, more than 100 stacker cranes, and 18+ kilometers of conveyor system. All IT, control, and mechanical components are developed and manufactured in-house at WITRON’s headquarters in Parkstein.

“From the very beginning, our goal was to create a leading-edge logistics platform that combines efficiency, sustainability, and supply reliability. By consolidating logistics in Wiener Neudorf, we are also setting the highest standards in digitization and automation of retail logistics”, says Isabella Handler, Overall Project Manager at REWE International AG, emphasizing the importance of technological implementation.

Construction measures – high sustainability standards

The project is also designed with sustainability in mind. Built exclusively on previously developed land, the logistics centre will become the new core of REWE’s logistics operations in Austria and a flagship project for the company’s logistics strategy. Construction is set to begin in the second quarter of 2026, with operations scheduled to start in 2031. Where possible, the new WITRON technology will be integrated into existing buildings. Demolition work will begin in parallel to pave the way for new buildings – all without additional land.

“In Wiener Neudorf, we are building the infrastructure of tomorrow – fully integrated in our nationwide network in Austria. REWE Group’s key objectives are to strengthen supply reliability and reduce CO2 emissions along the entire supply chain”, explains Christian Hörner, Managing Director of Warehousing & Transport at REWE International AG. The logistics centre in Wiener Neudorf marks a major step toward achieving these goals and will serve as a model for REWE Group’s international retail logistics operations.”

A long-standing partnership

“We are proud to be implementing this project together with REWE – a clear sign that the chemistry between our two companies is just right”, says Markus Lang, Project Manager at WITRON. “REWE and WITRON have enjoyed a successful project partnership since 2012. Currently, WITRON is supporting REWE Germany as an implementation partner in a major re-organization initiative at the Neu-Isenburg site, where a semi-automated Case Picking System with aisle-bound picking vehicles is being replaced by the fully automated OPM system featuring 22 COM machines. The REWE site in Henstedt-Ulzburg has also been equipped with WITRON technology and is considered a benchmark in REWE’s German logistics network.”

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With many school leavers fresh on the jobs market, the cross-border e-commerce and logistics company has announced that it will increase its number of apprentices to ten in the UK by 2030.

Despite investing in comprehensive AI and technical upskilling for existing talent, the recruitment drive for those starting out demonstrates the company’s commitment to the creative problem solving that it is famed for across the world.

Hiring New Talent

With recent Manpower figures showing that 76% of UK employers seeking talent in transport, logistics and automotive are facing skills shortages, Spring GDS, which has high employee satisfaction ratings across Europe is seeking to train and develop its own.

Kelly van der Weg, Managing Director of Spring Global Delivery Solutions UK said: “In these unusual times, the UK has the potential to become a still more important hub for international e-commerce providers seeking routes into Europe and the USA. Yet, behind every delivery there needs to be a team empowered by a culture of innovation, agility, and customer obsession.

“Rather than being held back by skills shortages, our ambition remains to attract, train and retain the best talent in logistics in the UK across the world. That means we need to engage talent at an early stage in their career, investing in international talent programmes, sharing knowledge and creating interconnectivity across markets. Empowering staff with technology but also listening to their new perspectives and creative solutions to help us make a difference on a global scale.”

The company has already reinforced its sales, marketing and business development with three new hires in recent months and three additional vacancies across its operations to fill.

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As the industry battles with high turnover and an ageing workforce, the physical demands placed on employees are drawing increased scrutiny. The latest government data shows nearly 40% of UK logistics businesses are struggling to fill vacancies. While automation garners attention, many warehouses still rely heavily on manual processes – and it’s here that equipment upgrades can have the most immediate impact.

“Better conditions start with better equipment,” says Phil Chesworth, Managing Director at Pallet Trucks UK. “If you’re asking someone to lift, push, and transport heavy loads all day, you have a duty to ensure they’re using tools that minimise strain and reduce injury risk. It’s a matter respect, efficiency, and staff wellbeing.”

The company has seen growing demand for ergonomically designed pallet trucks and scissor lift tables that reduce physical stress on workers. These pallets not only help to avoid workplace injuries – a leading cause of absence in logistics – but can also serve as a valuable retention tool.

According to the British Safety Council, musculoskeletal injuries remain one of the most common reasons for long-term sickness among warehouse staff. Providing safer, easier-to-use handling solutions shows a tangible investment in the workforce – which can make all the difference in an industry where margins are tight, and staff loyalty is often hard-won.

“As competition for labour intensifies, we’re finding that companies who invest in the wellbeing of their warehouse teams see better morale, fewer injuries, and greater staff retention,” adds Chesworth. “It’s becoming a competitive necessity, particularly for businesses that cannot afford to compete with industry giants when it comes to pay.”

For businesses looking to future-proof their workforce, investing in the right manual handling equipment could just be the smartest move they make in 2025.

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The pallet trucks, each with a 2.5-tonne load capacity and built to accommodate standard UK pallets, are part of a highly specialised and carefully managed contract. With complex technical requirements and logistical challenges, the order represents one of the most detailed and ambitious projects the business has undertaken to date.

Phil Chesworth, Managing Director at Midland Pallet Trucks, said, “Supplying the Ministry of Defence is an honour and a testament to the strength of our products and the dedication of our team. From the initial consultation to the final dispatch, this order required a huge team effort and close attention to detail. We’re immensely proud of everyone involved, from those in the warehouse building the trucks, to the staff coordinating transport, to those making sure even the smallest specifications were met.”

The pallet trucks, designed to handle the demands of tough industrial environments, will now be supporting operational efficiency across various military facilities. Built with durability and performance in mind, they offer low-maintenance reliability – critical for fast-paced, high-pressure settings like those operated by the MoD.

The scale of the order has seen multiple articulated lorries loaded at Midland Pallet Trucks’ distribution hub, with the first two trucks already enroute and twenty more to follow. Each truck had to meet strict technical requirements, down to the precise fork width, roller composition, and pallet compatibility.

This order is a glowing example not only of Midland Pallet Trucks’ commitment to quality, but also its ability to deliver on large, complex contracts. As the final deliveries roll out, this success story serves as a reminder that investment in robust, well-designed manual handling equipment – like pallet trucks, lift tables, and stacker trucks – remains a cornerstone of efficiency.

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Developed in partnership with Prologis UK, the project will consolidate Palletways’ operations, create space for future growth, and raise the bar for sustainable logistics buildings in the UK. The new site, located a short distance from the company’s current site at Fradley Park, will look to consolidate their operations in the area. Around 250 existing jobs will be secured for the Lichfield area, with the new facility set to create clear opportunities for further employment growth in the years ahead.

Palletways has been based in Lichfield since 1994, when it first established its operations in the UK. What began as a single site has grown steadily over the past three decades into a network that now supports more than 140 independent members and handles close to 6 million pallets each year.

Rob Gittins, Managing Director of Palletways UK, said: “Our decision to remain in Lichfield reflects the strength of our connection to the area and the role it has played in our success over the past 30 years. This new facility represents the next step in that relationship — creating space for growth while keeping us firmly rooted in the place where we began.”

By consolidating operations into a single, purpose-built site, Palletways will reduce handling times, improve tracking accuracy, support earlier finish times and more reliable delivery windows. The additional space and flexibility will also allow the business to trial new technologies and streamline logistics processes — helping its independent members operate more efficiently and deliver stronger service to their own customers.

Gittins added: “It has been clear for some time that we are outgrowing our existing site at Fradley Park, which has served us so well for nearly 30 years. We began looking at how we could secure local jobs with minimum disruption, create opportunities for long-term growth, and further strengthen our commitment to sustainability. We’re very excited about these plans, developed in partnership with Prologis, which reinforce all of those objectives. Our new headquarters will allow us to build on our service levels, provide better facilities and training opportunities for our staff, and offer even greater support to our members.”

A key factor for Palletways in selecting Prologis as development partner was the company’s ability to deliver sustainable logistics buildings that meet both environmental and operational needs — a close fit with Palletways’ ambitions for its new headquarters. This, backed by Prologis’ robust balance sheet and access to capital means that the development could be delivered for Palletways with confidence, once planning approval is in place.

The 640,000 sq ft facility will be delivered by Prologis and target BREEAM Outstanding and EPC A+ standards, placing it among the top-performing industrial buildings for energy efficiency. Features will include a 600kWp+ rooftop solar PV array, smart metering, rainwater harvesting, and high-efficiency systems to reduce both emissions and running costs. The new HQ has been designed with employee wellbeing and community connectivity in mind. The building will feature warehouse skylights to maximise natural light, alongside secure cycle parking and EV charging to encourage more sustainable commuting. A dedicated amenity space for Palletways workers will include soft and hard landscaping, seating and a covered area. A new cycleway and footpath, winding through natural landscaping and featuring native species will improve local access between Fradley and Streethay, creating benefits beyond the building itself.

Paul Weston, Regional Head at Prologis UK, said: “This is a development that supports jobs, productivity and sustainability in equal measure. It reflects the ambitions of a long-standing logistics leader, while also contributing to a cleaner and more efficient built environment. It also aligns with the UK’s broader goals to modernise infrastructure, support regional growth and enable more sustainable ways of working. By investing in high-quality logistics facilities outside major city centres, projects like this help strengthen local economies and future-proof the country’s supply chain network.”

The proposals are currently subject to planning approval. A public consultation is now underway, with a planning application expected to be submitted to Lichfield District Council in summer 2025. Subject to approval, construction is expected to begin in 2026, with occupation targeted for 2027.

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Bringing together the advantages of RFID Auto ID and in-mould labelling, Inotec’s RFID Inmould Labels offer durability, accuracy and sustainability. Developed in-house and tested in live customer applications, they are already helping leading logistics and packaging companies move away from single-use plastics while gaining full transparency across their supply chains.

Smart tray tracking at scale

A recent collaboration with EPT (Euro Plant Tray) demonstrates the real-world benefits of this solution. In the plant wholesale sector, over 95% of trays are currently single-use, contributing to around 40,000 tonnes of discarded plastic waste each year in Europe alone. EPT sought a reusable alternative that could deliver both environmental gains and digital traceability.

Working with EPT, Inotec developed a customised RFID inmould label that is seamlessly bonded to the reusable tray during injection moulding. This label offers exceptional durability – it is flush with the surface, waterproof, UV-resistant, and resistant to cleaning chemicals and mechanical impacts. Despite its compact size, it delivers a high-performance read range and allows bulk scanning of up to 1,000 trays simultaneously, with no line-of-sight required.

EPT’s trays now feature a secure, embedded RFID label that supports real-time tracking, inventory management, and cross-border reuse. The RFID inmould label is helping EPT reduce waste, optimise its processes, and set a new European standard for smart, reusable transport packaging.

Advanced performance, built to last Inotec’s RFID inmould labels are based on its own INO-TAG DIOBOND range and incorporate high-performance NXP RAIN RFID chips.

Key benefits include:

● High-speed scanning – multiple tags can be read simultaneously, even at distances of up to 15 metres
● No line-of-sight required – increasing speed and accuracy while reducing labour
● Secure, high-capacity data storage – with the ability to store encrypted tracking and logistics data
● Extremely durable – scratch-proof, smear-proof, waterproof and resistant to chemicals and temperature fluctuations
● Fully recyclable – made from the same material as the container for easier recycling
● Reduced energy use – thanks to in-mould’s one-step automated production process

Ideal for regulated and high-compliance sectors RFID inmould labels are particularly suited to industries where hygiene, traceability and security are critical. In food and pharmaceuticals, the edgeless bond eliminates contamination risk and withstands freezing, washing and sterilisation. IML is also compliant with strict FDA regulations and prevents label tampering or counterfeiting, which is critical for protecting intellectual property and public health.

“With RFID Inmould Labels, we’re combining durability, traceability and environmental responsibility in one powerful solution,” says David Stocker, General Manager at Inotec. “As seen with EPT, this technology helps our customers meet growing regulatory demands, streamline their processes and take a major step towards a circular economy.”

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As with most ecommerce businesses the speed and efficiency of the pick, pack and dispatch operation is vital, making all the difference to customer satisfaction levels and potential sales – particularly, at peak. For the managing director of UK Planet Tools, Bohdan Hrystayenko, this was an aspect of the business where he could see automation bringing significant cost savings combined with an uplift to productivity and it was the packing operation that held the greatest potential for a fast return on investment (ROI).

Labour savings

Having spoken with Sparck Technologies, Hrystayenko was aware of the major benefits, in the form of labour and materials savings, that could come from using automated ‘right-size’ boxing technology. Sparck Technologies’ CVP Impack auto-boxing system has the capability to tailor-make up to 500 boxes per hour, for multiple or single item orders, using advanced 3D scanning technology to optimally size, create and label each parcel in one seamless process – reducing package volumes by up to 50%, cutting cardboard usage by 30% and eliminating the need for void fill.

The technology was perfect for UK Planet Tool’s varied product profiles and mixed order quantities. The CVP Impack was highly flexible, capable of scanning and making boxes to the exact size needed for single item orders or multiple items, time and time again.

Why wait?

“This machine was exactly what we wanted,” says Hrystayenko. “Even though our daily throughput was only about half the capacity capable of the CVP Impack we knew we could reap enormous benefits from installing the machine now, rather than waiting. We were confident that with this machine in place we would have the operational flexibility and extra capacity to grow, without any fears over hitting peak volumes or trying to find additional labour. It was the right thing to do.”

An order for a CVP Impack was placed at the beginning of November 2024 and installed on 17th December, with ‘right-size’ packages rolling off the machine just two days later. “Space in the warehouse was tight but with some creative thinking from ourselves and Sparck we made it work. It was an incredible feat, supplying and installing the whole system in just eight weeks,” he says.

Big benefits

“The benefits for our business have been enormous,” says Hrystayenko. “With each box now custom-made to fit the exact dimensions of every order, we’ve eliminated the waste of shipping empty space. This alone has saved us 40% on consumables and material costs. Our reliance on manual labour has dropped significantly, transforming what was once a labour-intensive packing process. Like many ecommerce businesses, Mondays are our busiest days. Previously, we had to start early to clear the weekend backlog, but now we don’t begin until 8am. Thanks to the CVP Impack, just two operators can manage 250–300 packages per hour, removing the need for overtime and extra staffing.”

But for Hrystayenko, the most significant benefit from purchasing the Sparck’s CVP Impack has been the uplift in customer service, enabling a 5pm cut-off for a next-day delivery – a reliable fulfilment capability that builds customer confidence and wins new business. “The Trustpilot reviews have been glowing green ever since,” says Hrystayenko. “In fact, I calculate that had we installed the CVP Impack before the autumn peak we could have done 1.5x the business we did. This machine has given us the opportunity to grow the business. There’s no stopping us now.”

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IPP, which has its UK base in Coventry and specialises in providing reusable wooden pallets for major manufacturers and FMCG brands, is part of Faber Group, which has published its third annual sustainability report. IPP operates a closed pallet pooling network throughout Europe and its pallets – known as load carriers – are built using FSC/PEFC certified timber and maintained to optimise their lifespan.

Faber Group supported 131 million load carrier movements across Europe in 2024 – a substantial increase of 11 per cent, or 13 million movements compared to 2023 – all while successfully reducing overall carbon emissions. The companies have implemented an Environmental, Social and Governance (ESG) strategy with three clear sustainable development goals to help them achieve an ambitious target of becoming net zero by 2045.

The three key areas it is working on to improve sustainability include responsible production and consumption, climate action and partnerships.  Priority actions include reducing transport emissions via its pallets, reducing the footprint of its logistics operations by 30 per cent by 2030 and maximising the lifespan of its pallets to reduce production and consumption.

IPP has already made substantial progress to reduce emissions from its logistics operations by becoming the first company to achieve a European two-star Lean and Green rating. The Sustainability Report 2024 demonstrates that its circular economy business model is driving real change and real benefits for the environment.

Andy Maddock (pictured), regional managing director for IPP UK&I, said: “The third edition of Faber Group’s Sustainability Report shows the further integration of our ESG pillars across the business and how they are delivering sustainable value for IPP and our customers. We are proud of our collective progress in reducing our carbon emissions while working towards our goal of net zero. Collaboration, digitalisation and sustainable procurement will continue to be key drivers in enabling us to realise our ambition and deliver change with real impact.”

Ingrid Faber, CEO of Faber Group, said: “In 2024, we were able to help our customers avoid more than 40,000 tons of CO₂ emissions through our circular pooling model, a steady increase of more than eight per cent of saved emissions in comparison to 2023. We also retained our EcoVadis Platinum rating, placing Faber Group in the top one per cent of its industry for the fourth consecutive year. The launch of our tech division Faber LABS and investments in digitalisation further strengthen the company’s ambition to become Europe’s most sustainable pooler.”

IPP has a wealth of eco credentials, including a platinum Ecovadis sustainability rating, a Lean and Green two-star European rating and is a signatory to the United Nations Global Compact – a voluntary initiative to implement universal sustainability principles.

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The T-sorting robots are set to be operational in September 2025, providing THG Fulfil with the capacity to output c1 million units per day – a move that will strengthen THG Fulfil’s ability to manage peak demand as it onboards new brands and retailers ahead of the holiday season.

THG Fulfil provides solutions by seamlessly integrating automation, AI-driven technology and proprietary software, delivering customer satisfaction. The strategic implementation of Libiao’s innovative robots is testament to THG Fulfil’s commitment to leveraging advanced automation to enhance speed and improve efficiency across its ecommerce operations. The modular and flexible design of the T-sorting system allows for dynamic scalability, enabling THG Fulfil to rapidly adapt to fluctuating consumer demand, regardless of seasonality.

Libiao’s T-sorting robots are renowned for their high stability and fault tolerance capabilities, boasting a remarkable sorting accuracy of up to 99.9%. The system is engineered to sort for multiple destinations simultaneously, with electroplating robots operating on optimal paths to maximise sorting efficiency. The technology also offers significant space-saving advantages due to its low footprint requirements and versatile deployment options across warehouse levels.

Furthermore, THG Fulfil is Libiao’s UK distribution partner, enabling brands and retailers to access Libiao’s cutting-edge robotics solutions and benefiting from THG Fulfil’s proprietary technology, optimisation and know-how. Brands and retailers will also benefit from rapid deployment capabilities, with installation of Libiao’s robotics solutions possible in as little as three weeks. This short project cycle contributes to fast and high return on investment, resulting in a typical return period of less than three years.

Tom Killeen, COO, THG Ingenuity, said: “We have always believed that fulfilment is a core driver of customer excellence and brand reputation. Our collaboration with Libiao further solidifies our commitment to providing brands and retailers with industry-leading, scalable automation solutions that optimise everything from pick and pack to final mile delivery, ultimately enhancing customer experience and driving loyalty. Our unique approach, which often sees 95% of all units sold moving through some form of automation, combined with our late NDD cut-off times of up to 1am, is truly what sets us apart. We are committed to investing in the future of logistics, while empowering our clients to meet and exceed evolving consumer expectations with unparalleled efficiency.

Jason Zhang, VP of Sales – Europe, Libiao, said: “We’re excited to partner with THG Fulfil, showcasing the elegance and scalability of Libiao Robotics’ solutions. Our compact, modular robots enable rapid plug-and-play deployment. With THG Fulfil as our UK distribution partner — leveraging their vast retail network and warehouse automation expertise — we look forward to expanding Libiao’s reach across new industries. At Libiao, our mission is to make the world more efficient, and this collaboration is a meaningful step toward that goal.”

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Hugo Beck, a manufacturer of horizontal packaging machines, has announced the appointment of Simon Beck and Jonas Beck as Managing Directors. As grandsons of company founder Hugo Beck, they represent the continued leadership of the family business in its third generation.

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