At Vergeer Holland's state-of-the-art processing facility cheese is processed fully automatically, from in-feed to pallet.  In a sector where hygiene, efficiency and scalability are critical, Vergeer Holland opted for a complete transformation. The newest processing facility in Bodegraven is designed for maximum automation with minimal manual labor.

Vergeer Holland is one of the largest, innovative cheese processors in the world. At their facility in Bodegraven cheese is treated, cut and packaged. Link Magazine spoke to Vergeer and DERO GROEP about smart solutions in this factory. "Our ambition was to no longer touch the cheeses by hand," says Dennis Vergeer, raw materials manager and third-generation member of the family business. "To prepare for the future, we're investing heavily in robotics and automation."

 Future-proof from the start

"The timeline for growth depends on many factors," Dennis continues. "It starts with the right system design. But it also requires partners who don't just deliver what's asked, but help think ahead." DERO GROEP was involved from the earliest phase as an innovation partner, delivering various smart systems for cheese handling, treatment and processing.

"The focus was on the future right from the start," says Maro Dedel, CEO of DERO GROEP. "What can we automate today, and how do we ensure the solution is ready to scale with Vergeer Holland's ambitions?" In the brand-new factory, more than 600 tons of cheese are processed every week. Everything is geared towards hygienic, efficient, and scalable operations. The goal? Full automation, with minimal manual handling. "The biggest gain is that we need fewer people," Dennis adds.

Pushing boundaries together

During ripening, each cheese is turned and coated every three days. "Vergeer really challenged us there and included us in their ambition to reach the next level," says Maro. "Our standard cheese treatment line had a capacity of 650 cheese shelves per hour. That had to become 850 per hour. It took a lot of work, but in the end we succeeded. We never run away from a challenge, but you also need customers to push you. Then you see that you strengthen each other in a good cooperation."

Cheese processing and handling at Vergeer Holland.

Smart handling in every step of the process

Once the cheese reaches the desired age, it is retrieved from the warehouse and processed further. One of the most versatile systems supplied by DERO GROEP is the supply robot. It features gripper change systems and can handle different types of cheeses and carriers. The robot communicates with the WMS system, automatically switches during product changes, and determines how many cheeses still need to be unloaded.

The box-to-box line also includes advanced control systems. Each delivered box is automatically checked for the correct type. According to Mark Pronk, project manager at DERO GROEP, this was the first time such a control setup was applied in this way. "From every package, bag, or box that leaves the factory, we can trace exactly which cheese it came from," Dennis explains.

Technology tailored to practice

Automating a factory with so many cheese formats and carriers was challenging. Every system had to be reliable and flexible, even when data wasn't perfect. DERO GROEP delivered lines that operate fast, precisely and hygienically, and can be easily adjusted for different products. A key result are the universal supply robots. "We configured the software so that all robots are technically the same, despite small functional differences," says Mark. "That setup is now running in eight robots."

Shared drive for automation

Even in a fully automated factory, people remain essential. "There’s still a lot of technology in these machines that our operators aren’t familiar with yet," says Dennis. DERO GROEP supports the process with training, tooling, and software like DGStatistics that enables data-driven optimisation. The collaboration with Vergeer Holland is marked by mutual trust and a shared drive. "Everyone had the mindset that we needed to make this work together," Mark says. "We all went the extra mile for each other."

"On day one, the entire cleanroom was empty," Mark adds. "Now, just a few years later, the floor is nearly full. It's hard to imagine it was ever empty."

The strength of this collaboration lies in commitment, technical expertise, and a shared vision for the future. With smart automation as a foundation, Vergeer Holland is ready for the next step.

Source: Link Magazine, www.linkmagazine.nl