Greenfield picking

Test and rearrange –
procedures of picking in bigger bakeries


In the past 10 years, bakery A has continually grown and now supplys 39 of its own branches and many resellers. This includes the local hospital, as well as schools and various smaller customers. The current production facilities are state-of-the-art.


Owners and production managers don’t have an easy decision when it comes to selecting the right oven or lamination technology. However, conceiving and planning the right picking process is even harder. Kneading, baking and frosting is the key business at bakeries and not picking, dispatch and logistics. Additionally, bakery goods must also be handled gently and with care which means it is necessary to shift the attention to how a dispatch concept pans out.


Even obvious, hand-written concepts or those animated on screens can only help decision-makers to a certain extent, as it still isn’t possible to assess whether or not these concepts will actually work in reality.

Develop and check –
picking system by piece production

Bakery B
is a specialty bakery, let’s say an organic bakery. Years ago, this bakery operated a small number of its own branches. However, with the growing success in the organics segment, the number of branches went down year by year. At the same time, sales grew among a number of resellers. Today, the company supplies its 35 different bread sorts and bakery goods to a total of 320 organics stores, health shops and weekly markets, as well as a range of small one-time customers. All customers can order the bakery goods by the piece.


A Pick-to-Light system, also referred to as the „shopping method,“ would fit this product and customer structure. Similar to shopping at the supermarket, this method describes the process of moving along aisles with a shopping cart, picking the products noted from your shopping list. However, this would require enough goods of each type to be available on initial distribution! Since the products have to be as fresh as possible on delivery, the company can’t just move production to an earlier time. If that were the case, these batches may already be stale by the time they are delivered.


Since it isn‘t possible to provide all products at bakery B early on, toolbox is unable to suggest a “pure” Pick-to-Light method here. Instead, we create a solution tailored to the customer’s situation. From a theoretical perspective, the solution adapted for bakery B would be very successful.

Expand and improve –
picking methods for fresh goods


Bakery C has already worked with great success with dispotool in picking bread, rolls and pastries for many years. A total of 40 customer spaces are set up in the fresh goods area. Each customer has a space equipped with matrix displays. In recent years, the sales of frozen products baked in their own shops has grown continually. Though this amount of growth was desirable, it was not planned. Although the dispatch process for the fresh products worked wonderfully, bakery C resorted to long abandoned traditional methods for frozen goods - picking the frozen products using a common paper-based process with dispatch notes.


In future, this inefficient method will also be changed to dispotool. Another requirement of bakery C was to organize the picking of retail goods and the shop’s requirements. The frozen goods area will be equipped with displays resistant to cold and humidity. With the existing dispotool system - used to dispatch fresh breads and rolls using the Put-to-Light method - the concept will be expanded so that frozen foods will be picked in the Pick-to-Light system, and retail goods by Pick-by-Vision with smart glasses.


Your service benefits

To change processes is always difficult

A production machine sticks to programmed and given methods – no matter what. However, a person in picking may not when used to other processes. In the toolbox Dispatch Academy, an old hand can learn new tricks and new methods, and take their time to practice – regardless of ongoing operation in the bakery – but with a virtually identical, thus familiar dispatch environment.

The proof is in the pudding

It’s details that are most difficult. Despite the fact that toolbox has optimized over 800 dispatch departments of all sizes and complexities since 1996 thus gaining vast experience - there are still minor areas for improvement. Over the past 20 years, these changes were made during ongoing operations at the bakery. With the toolbox Dispatch Academy, these settings can be discussed, configured and tested before installation and independently to day-to-day business.

No great imagination is required

In virtually all consultation meetings, you will hear the sentence, “Now just imagine...” Easier said than done! The customer and the decision-maker in the bakery have the picking process of their bakery in mind, and know the difficulties and snares in day-to-day business from hundreds of experiences. toolbox doesn’t want to exhaust your imagination too much. In the Dispatch Academy, you can test live and without “a safety net” how your picking process could be in the future.

All for free, but not for nothing!

The Dispatch Academy is free-of-charge for interested bakeries, regardless of whether you want to “work” in the 250 m² dispatching hall during the week or on a weekend. No matter whether you’d like to use the Academy alone or with several employees – toolbox will even provide the toolbox apartment for two employees free-of-charge. All it costs you is the travel expenses and, of course, the time you invest.

You would like to receive more information about the toolbox Dispatch Academy? Write us an e-mail to This email address is being protected from spambots. You need JavaScript enabled to view it.