Greenfield Solution: Automated Logistics Facility from SCIO Automation at Pappert Bakery
With the new baking facility at Pappert Bakery in Eichenzell, SCIO Automation has implemented a fully automated greenfield logistics solution that covers the entire container cycle of a large-scale bakery. The intralogistics experts at SCIO Automation were responsible for the end-to-end implementation, from planning and development through installation and commissioning. Spanning three levels, the system integrates empty container receipt, cleaning, storage, and production supply into a closed-loop material flow—designed for high throughput, food hygiene, and future growth.
Holistic System Integration as a Key Success Factor
A new building on a greenfield site can be planned consistently around the material flow, rather than having to retrofit automation into existing structures. The Pappert Bakery and SCIO Automation worked together on this from the very beginning. The decision to choose SCIO came from within the industry. Before planning began, management visited various bakeries and heard the same name time and again. According to Vincent Pappert, it became clear during the very first meeting with SCIO Automation that both sides were pursuing the same goal.
The result is a three-level system that integrates destacking, washing technology, an automated basket storage system, connecting conveyor technology, and the supply of three production levels into a single comprehensive system. The building’s structure dictated this multi-level architecture: basket delivery takes place in the basement, while the storage area is on the upper floor. This meant that basket transport had to be managed across multiple floors. Doing this manually, as was customary in the past, would no longer be feasible given today’s production volumes.
A Closed Loop Instead of Individual Stations
The logistics of a chain bakery operate in a cycle: what leaves in the morning as merchandise returns as empty containers. Over 170 specialty stores in Hesse, Bavaria, and Thuringia contribute baskets and trays to this return flow every day.
Automatic destackers separate the delivered stacks and transfer the baskets in mixed batches and the trays sorted by type to the conveyor system. From there, they continue on without any manual intermediate steps until they return to the stores as load carriers for the baked goods. The interfaces are automated. The cycle is seamless.
One step in this cycle is particularly critical for food production: the cleaning of the containers. The integrated washing line processes up to 2,000 baskets and trays per hour and is thus designed to match the capacity of the downstream production supply system. Washing technology, conveyor systems, and storage are coordinated so that cleaned containers continue through the process without bottlenecks.
The basket storage system as the heart of production supply
At the heart of the system is an automatic basket storage system with a capacity of up to 60,000 containers. It decouples the irregular return of empty containers from the stores from the production line’s scheduled demand, buffers out peaks, and makes each container type available as soon as the respective line requests it.
From there, the system supplies three production lines: up to 2,400 trays per hour to the roll production line, 1,200 baskets per hour to the pastry production line, and 1,200 baskets to the large oven. After the baking process, it retrieves the finished goods and transports them via the order-picking area to the exit.
“When it comes to the basket warehouse, you can simply say: If that’s running, if it’s ticking like clockwork, then everything else runs smoothly too. If all the production lines are supplied from there, then the entireproductionruns smoothly,” says Vincent Pappert, a member of themanagement team at Pappert Bakery.
Relief for Employees
The most noticeable effect isn’t in the metrics, but in the day-to-day work, with a daily output of around 150,000 rolls alone. Previously, the baskets and trays had to be moved and transported by hand. Now, the trained staff can focus entirely on product quality; the logistics system takes care of the rest.
It’s remarkable how quickly the staff has embraced the new system. What began as a completely new automation process is now an integral part of everyday operations, explains Vincent Pappert.
Modular Design, Scaled for Growth
The system is modular in design and expandable, which has been a key criterion for Pappert Bakery since its first meeting with SCIO Automation. A look ahead shows just how concrete this requirement is. An expansion of the existing warehouse has already been commissioned for next year. The scalable system architecture ensures that the intralogistics can adapt to rising production volumes and additional branches.
Vincent Pappert takes one key recommendation from the project for other bakeries: Logistics planning should come at the beginning, not the end. If the building is already in place while the logistics concept is still undecided, the scope for adjustment narrows considerably.
The Project at a Glance
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Fully automated greenfield logistics solution on three levels
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Automated basket warehouse with a capacity of up to 60,000 containers
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Washing line for 2,000 baskets and trays per hour
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Up to 2,400 trays per hour fed into roll production
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1,200 baskets per hour fed into the pastry production line
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1,200 baskets to the large oven
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Modular, expandable logistics system
Automation in the Service of Artisanal Craftsmanship
With its new bakery in Eichenzell, Pappert Bakery combines artisanal production with industrial-level intralogistics.
“We’ve created a new production facility that can grow with us, makes our employees’ work much easier, and ensures even better quality for our customers,” says Vincent Pappert, a member of themanagement team at Pappert Bakery.
With this facility, Pappert Bakery has achieved one of the highest levels of automation in industrial bakery production in Germany.
Meet us at südback 2026
We’d be happy to discuss in person at the event how customized logistics solutions for the food industry work in practice and how precisely tailored automation provides a significant competitive advantage.
📍 südback 2026, Stuttgart (GER)
👥 SCIO Automation
📅 June 24–27 | Booth 8D69
Stop by and see our logistics system for Pappert Bakery in a comprehensive visualization!
You can also experience our Taro warehouse system live on-site!
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