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How SIMOVE Fleetmanager scales up automation at Soudal

As Soudal doubled production capacity, they wanted an open and scalable AGV solution. SIMOVE Fleetmanager delivered.

‘Build the future.’

Soudal had quite the ambition for its new Plant 5. It needed a smarter, safer, and scalable way to move heavy mixing vessels – some weighing up to 2.5 tons – across the new 20,000 m² production facility. Supported by Actemium Handling Solutions and Siemens, the company implemented an AGV system built on open standards. The result: a logistics operation ready for the next decade.

The challenge: Automating production and transport

With a 20,000 m² floor area, Soudal’s new plant 5 is ready to support the company’s expanding production of sealants and foams. “We wanted to automate as much as possible,” project engineer Jo Maes explains. “Automated production equals less energy usage, less waste and most importantly: a safe and ergonomic work environment.”

Soudal’s products consist of powders and fluids that are mixed in large mixing machines. The fluids are stored in large vessels, weighing up to 2.5 tons. And yet, dosage is critical as hardening chemicals cause the mixers to jam and the product to go to waste. “That’s why we automated the dosing process. Next step was automating the logistics with autonomous guided vehicles (AGVs). Manually moving loads of that weight presented risks, both for safety and for product integrity.”

About Soudal

The Soudal Group is the largest independent European manufacturer of sealants, adhesives and polyurethane foams for professional and private users. This Belgian family business, based in Turnhout and founded by Vic Swerts in 1966, has grown into an international player and expert in chemical construction specialties.

About Actemium Handling Solutions

Actemium Handling Solutions (formerly AVT Europe NV) is an Essen-based company specializing in heavy load transport, machine building and customized robot and integration projects.

A multi-stage approach

Additionally, Soudal anticipated a phased expansion of its AGV fleet over time, including new vehicle types and transport tasks. Any fleet management solution would have to accommodate that evolution without starting from scratch each time. In a first phase, Actemium Handling Solutions built 2 AGVs for powder transport; the second phase involved 2 different AGVs for fluid transport. They both communicate directly with the manufacturing execution system (MES), eliminating errors. An integrated RFID reader keeps track of each production batch.

“We had already collaborated with Actemium Handling Solutions in plant 1, for pallet handling,” Jo continues. “This project was more complicated: we wanted two types of AGVs, for the powder and for the fluids.”

“We were glad to take on this project,” says Tom Bergmans, sales manager Actemium Handling Solutions. “Custom built AGVs are what we do best. Both Soudal and Actemium Handling Solutions are Siemens standardized. As a result, communicating with the dosing automation system was very easy.”

Soudal - automating transport

3 key features of the Soudal automation project

Soudal - Jeroen Pieters

1. Open system built for flexibility

The AGVs are coordinated by the SIMOVE Fleetmanager: a WinCC OA-based software package that tracks the AGV’s and tells them where to go. “SIMOVE Fleetmanager uses VDA 5050, an open protocol to coordinate movement,” says Jeroen Pieters, account manager Siemens.

“An open protocol was a must-have in this project,” Tom confirms. “With different types of AGVs, you quickly end up with different fleet managers for each type. Furthermore, Soudal wanted to avoid vendor lock-in. If they ever wish to add AGVs from other vendors later on, that’s possible, as long as these vendors are VDA 5050-compliant.”

2. Scalable and future-proof

“SIMOVE Fleetmanager is also an open-source platform,” Tom continues. “This enables us to program features ourselves, which we did in this project, for integrating non-standard wheels in the AGVs. Closed platforms require reverting to the supplier for each modification: slow and cumbersome. SIMOVE is really the best of both worlds: agile and backed by a large supplier.”

“And it’s scalable,” Jeroen adds. “At the moment, four AGVs are running simultaneously in SIMOVE Fleetmanager. But there are projects where we control up to 300 AGVs.”

“This openness allows us to continue the automation as we expand production,” says Jo. “We envisioned the routes for the two AGV types from the start of the building project, but we can’t predict the automation technology ten years from now. SIMOVE Fleetmanager is completely customisable and future-proof.”

Soudal - Tom Bergmans
Soudal - Jo Maes

3. Part of a large portfolio

Another important factor was SIMOVE’s alignment with the existing plant architecture. Like the rest of the production line, SIMOVE runs on Siemens technology: WinCC OA, industrial PLCs and wireless communication systems already used in the plant.

“This made it easier to connect the fleet manager with the manufacturing execution system (MES) and reduced the need for separate maintenance or support structures. It also gave our internal engineers more confidence in eventually taking over system ownership. And whenever we or Actemium Handling Solutions need help or advice, Siemens was there.”

We don’t know what our automation needs will be ten years from now. But with SIMOVE, we’re ready.
Jo Maes, Project Engineer, Soudal

Results

The first four AGVs are already making a real impact at Soudal.

  • Improved safety and ergonomics, as manual movement of heavy containers is eliminated.
  • Fewer process errors, thanks to automatic task handling linked to the MES.
  • A scalable setup, where new AGVs can be integrated with limited rework.
  • Operational independence, supported by an open protocol and standard technology stack.

“Comparing the production of plants 1 and 5 is comparing apples and oranges, because the sites are completely different,” Jo explains. “But we’ve certainly achieved a safer and healthier work environment, while improving operational excellence. In the next years, we’re ready to continue automating.”

Soudal - results