Introduction: when production logistics cannot slow down
Duvel Moortgat is more than a brewery. Founded in 1871, it is one of the world’s most renowned independent brewers, custodian of iconic brands such as Duvel, La Chouffe, Vedett, Maredsous, and De Koninck. With over 20 brands distributed across Europe, the United States, and China, Duvel operates in highly diverse markets with different consumer demands, regulations, and distribution dynamics.
This global scale comes with a challenge: ensuring production logistics continuity under any circumstance. In brewing, seasonal peaks and product launches concentrate enormous volumes into short time windows. In this context, even a minor inefficiency in spare parts management or set-up tools can disrupt the entire flow — delaying deliveries, increasing costs, and impacting customer satisfaction.
The problem: traditional storage slowing down production logistics
At the historic Puurs-Sint-Amands site in Belgium, Duvel managed around 5,000–6,000 spare parts and machine set-up components. Traditional static shelving presented several issues:
- 4–5 operators across three daily shifts dedicated to parts picking;
- over 10 minutes required to retrieve just 5 items;
- no real-time tracking of stock;
- congested storage space reducing agility in production logistics.
The consequence? Frequent delays in machine set-ups, downtime risks, and inefficiencies precisely during peak production, when every minute counts.
The solution: SILO² vertical lift module
To overcome these bottlenecks, Duvel Moortgat replaced static shelving with a SILO² multi-column vertical lift module (VLM) from ICAM, a solution that goes beyond storage and becomes an integral part of production logistics optimization.
Key features include:
- 5.5 m height with 3 storage columns, suitable for compact spaces or outdoor installation;
- 144 trays, each with 400 kg capacity (1,953 mm width × 802 mm depth);
- Dual access bays with the interactive picking system IRIDE, guiding operators visually and reducing errors;
- ICON software integrated with Duvel’s ERP system, providing secure access, automated lists, and full material traceability;
- Only 21 m² footprint, reducing storage area by 70% and freeing valuable production space.
Smart integration: software + real-time visibility
The integration of ICON with Duvel’s internal ERP was a turning point. The SILO² is not just storage, but a central hub for production logistics, enabling operators to:
- process picking lists using barcode scanners or digital interfaces;
- receive real-time inventory updates;
- synchronize flows between warehouse, production, and maintenance;
- eliminate errors and downtime caused by manual handling.
Tangible benefits for production logistics
The impact of SILO² was immediate and measurable:
- 70% faster picking: from over 10 minutes down to 3 minutes per list;
- 70% less space required: 6,000 items stored in just 21 m²;
- zero machine downtime caused by missing or delayed parts;
- faster machine set-ups, ensuring a smooth production flow;
- operators reassigned from repetitive tasks to higher-value activities.
A foundation for international growth
Jan Geelen, Manager Services & Solutions at Dexis (Authorized Dealer of ICAM), explains:
“With SILO², Duvel Moortgat streamlined its internal flows, guaranteeing speed, accuracy, and operational continuity. In a sector where every minute counts, this solution made the difference.”
By adopting SILO², Duvel Moortgat turned a storage weakness into a production logistics enabler, ensuring operational continuity and supporting its international growth.
Why this matters for space-constrained companies
Duvel’s case is particularly relevant for companies that:
- have limited production space and need external warehouse installations;
- face complex production logistics challenges;
- require ergonomic, safe, and operator-friendly working conditions;
- want a fast ROI by reducing downtime, errors, and wasted floor space.
Conclusion: smarter production logistics, uninterrupted brewing
Thanks to SILO², Duvel Moortgat made its production logistics smoother, faster, and safer, turning inefficiency into competitive advantage.
The lesson is clear: for companies with limited space but ambitious growth, vertical storage systems installed indoors or outdoors are the key to scaling operations without physical limits.
FAQ – FREQUENTLY ASKED QUESTIONS
What are the benefits of vertical storage systems for production logistics?
They drastically reduce picking and set-up times, optimize floor space by up to 70%, improve traceability, and ensure production continuity during peaks.
Can vertical lift modules be installed outside the factory
Yes. Solutions like SILO² can be installed outdoors, with access bays connected to the inside via a wall opening, keeping operators safe and workflows unchanged.
How do vertical storage systems reduce downtime?
Integrated software and guided picking systems ensure that parts are located within seconds, eliminating delays that would otherwise stop or slow down production.
Are vertical lift modules suitable for companies with little available space?
Absolutely. SILO² manages thousands of items in as little as 20–25 m², freeing production areas for higher-value activities.
What is the ROI of a vertical lift module?
On average, companies achieve ROI within 12–18 months thanks to time savings, reduced floor space, and fewer machine stoppages.
Want to find out how to optimize your seasonal logistics? Contact us