Food Australia
Map
OVERVIEW OF FOOD
WAREHOUSING AND STORAGE
SERVICES IN AUSTRALIA
November 2014
nsert image herePrepared by
The Institute for Supply Chain and Logistics
Victoria University, Melbourne
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makes no express or implied guarantees, representations or warranties to any third party
as to whether the requirements of this document will be fulfilled by VU, its employees,
agents or contractors or anyone else to whom the document relates. VU accepts no
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This document is a proprietary document and the property of VU.
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1.
INTRODUCTION
Food Australia Map is a project of the Victoria University Institute for Supply Chain and
Logistics in collaboration with Food Innovation Australia Ltd.
The project will create a repository of information on food transport, distribution and
storage across Australia, detailing supply chain services available to food producers,
manufacturers and suppliers.
The information will be available as a searchable on-line tool capable of displaying food
industry supply chain services across the country by features such as location, temperature
requirements, specialisation (eg wine, confectionery) and geography serviced (eg.
metropolitan, import-export).
In the case of warehousing and storage, a food manufacturer or producer seeking short
term seasonal or overflow storage can search and make contact with suppliers of this form
of storage in proximity to manufacturing, distribution and retail sites.
The data is hosted by the Victoria University Supply Chain Information Unit.
The pilot database is classified by ANZSIC code 5309: Warehousing/Storage Services
and in this case, applies only to food quality warehousing and storage. For this category
of food supply chain service, a range of data has been collated as follows:
•
Temperature – ambient; chilled; frozen
•
Warehouse size – this may be recorded as square metres, cubic metres in the case
of frozen product held in rooms or bays; or pallet capacity available
•
Specialisation – if a warehouse has a specific product speciality it is recorded
•
e-Commerce – the warehouse services e-commerce activity
•
Consignment size – this may range from items, cartons, pallets, containers or
truckloads
•
Company Name and contact details, including email and website address
•
Coverage – some 3PL suppliers have warehousing available nationally, other
provide short terms storage for import or export activity
•
Unpack and receipting – container unload; product receipt; including proof of
delivery (POD); BBD stickers and product codes; client IT interface
•
Quality assurance – fumigation; pest control; insulation; retention samples;
retention laboratory
•
Storage – security; short or long term; rack or block; stock rotation; stocktake and
cycle controls; re-work and re-pack; returns
•
Order assembly – EDI capable; integrated order process; pick and pack; labelling;
creation of delivery documentation; organise transport; container load; cross
docking
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•
Reporting – stock in hand; stock movements; replenishment reports; forecasting
•
Other services – detail of additional offerings is recorded
Food consumption in Australia occurs through a number of channels, as follows:
Master channel
grocery
retail
convenience
specialised
Sub-channel
Full-service supermarkets
2,285
Independent supermarkets
1,950
Independent stores
3,600
Convenience stores
2,100
Bakery, cake and pastry
6,450
Delicatessen
1,760
Butcher, poultry, seafood
5,800
Fruit & vegetables
2,400
Liquor merchants
4,700
Sandwich bars
takeaway
dining out
foodservice
event/leisure
institutional
Independent takeaway
12,800
Quick-serve restaurants (QSR)
6,400
Restaurants & cafes
20,450
Pubs, clubs & function centres
2,700
Event, leisure & travel
2,500
Accommodation
6,950
Hospitals
1,300
Aged care
2,400
Defence
80
Correctional
125
Corporate (workplace)
1,350
Education
9,500
Source: Australian Government, Dept of Agriculture, Forestry & Fisheries, 2012
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Specialist Food
Stores, 12.0%
Supermarkets,
62.8%
Breakfast, 1.4%
Lunch, 8.2%
Dinner, 11.5%
Snacks, 4.2%
Source: Freshlogic 2011
Food supply channels are largely dominated by supermarket volumes, with almost two
thirds of supply moving through this FMCG retail mode and it’s warehousing and
storage system. However, the dominance of multi-user, outsourced warehousing over
dedicated warehousing indicates the trend towards a more flexible model of 3PL
warehousing for the large food retail sector.
Food warehousing and storage composition in Australia
Dedicated FMCG
Foodservice & catering
3PL
Source: VU ISCL, 2014
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2.
FOOD WAREHOUSING AND STORAGE MODELS
Source: Supply Chain Guide 2013 www.logisticsbureau.com
Warehousing and storage can perform a range of functions in the supply chain.
Warehouses may be operated to store inbound product and raw materials for food
manufacturing or for outbound finished product destined for retail distribution, export or
increasingly, direct to consumer delivery.
Warehousing generally costs between 1.25 and 2.25% of the value of sales. A highperforming warehouse solution should be at the lower end of this cost envelope.
Warehousing is provided on the basis of:
•
Fixed price
•
A percentage of sales or goods value
•
Based on activity – rates set for SKUs; stock movements; services provided
•
A mix of fixed and variable costs
•
Free of charge, with other services imbedded in the storage costs.
Food quality storage and warehousing is provided using the following models:
2.1 On-site storage facilities at food manufacturing plants
An example of this model is Tatura Milk, where significant investment has been made in
an on-site warehouse with a 15,000 pallet capacity co-located with the dairy
manufacturing operation.
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http://www.tatura.com.au/Manufacturing/Factorytour.aspx
Murray Goulburn Cooperative Co Ltd. has leased a major Integrated Logistics Centre
located at Laverton North in Victoria and a Global Distribution Centre at the Port of
Melbourne. The centres receive products from coop processing plants and prepare them
for distribution and export. A major new processing plant is being built alongside the
Laverton North logistics centre.
From these warehouses, distributors are serviced and arrangements are made for
transport to FMCG retail distribution centres or outlets.
2.2 Major and composite distribution centres
The largest format storage for food is in distribution centres leased or outsourced to 3PL
suppliers by major food retailers. Distribution centres are operated directly by food
manufacturers or producers or more commonly outsourced to a 3rd party logistics supplier,
termed a 3PL.
For example, Arnotts has 5 distribution centres across Australia, under the contract
management of Linfox. The newest is located at Bungarribee Industrial Estate on the Great
Western Highway in Huntingwood, NSW.
http://au.goodman.com/property/development/pipeline/bungarribee-industrial-estate.
Martin Brower undertakes distribution for the Mcdonalds fast food restaurant chain. It
operates 7 distribution centres across Australia in Dandenong South (3164); Rocklea
(4106); Kings Park and Blacktown (2148); Heatherbrae (2324); Banjup (6164) and
Gepps Cross (5094).
National distribution centres are typically large footprint warehouses of 30,000 –
90,000m2 on sites ranging from 8 to 12 hectares with good access to major road
arterials and often inter-capital rail lines. They commonly offer composite or multitemperature storage areas, rack and block storage and sophisticated warehouse
management systems that integrate with retailer and supplier enterprise resource planning
systems.
They receive product from suppliers to be re-configured and distributed to a network of
retail outlets/supermarkets. National Distribution Centres service the larger metropolitan
regions, and Regional Distribution Centres tend to service the regional areas and smaller
capital cities.
The following summary of retail food distribution centres indicates the size and spread of
these facilities:
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COLES
NSW –
Eastern Creek (2766 NSW) NDC ambient & liquor 73,256m2 and
Chilled/Frozen DC 36,890m2; Smeaton Grange (2567) ambient 62,407m2; Goulburn
(2580) Regional DC 42,500m2 on 13.6 ha
VIC – Somerton (3062) ambient & liquor (operated by Toll Group) 70,000m2; Truganina
(3029) NDC ambient (operated by Linfox) 80,000m2
QLD – Forest Lake-Heathwood (4110) ambient/liquor 50,000m2; Parkinson (4115)
chilled & frozen 45,000m2
SA – Edinburgh Park, Salisbury (5111) RDC – ambient, liquor, chilled, frozen 67,944m2
WA - Kewdale (6105) NDC 87,241m2.
Polarfresh is a joint venture between Costa Logistics and Swire which operates fresh
produce DCs for Coles in Truganina (3029 VIC) handling 1.4 million cartons of product
per week to 216 stores in Victoria and Tasmania; Eastern Creek (2766 NSW) and
Parkinson (4115 QLD). Carter and Spencer operate the fresh produce DC in Townsville
for Coles in Bohle (4818 QLD). In WA and TAS, Costa Logistics operates the fresh
produce DCs at Jandakot (6164 WA) and Quoiba (7310 TAS). In SA, St George Produce
operates the fresh produce DC for Coles servicing SA and NT in Burton (5110 SA).
WOOLWORTHS
Woolworths generates 20 million cartons of product each week and 3,000 truck
movements per day.
Woolworths is implementing its Mercury 2 logistics strategy. Woolworths has a 75% share
in Australian Leisure & Hospitality Group, which operates 320 licensed venues and
gaming operations across Australia. In addition to its supermarket network Woolworths
has Big W, BWS, Dan Murphys, Wine Market, Cellarmasters, Langton’s and Thomas Dux.
Woolworths also has an on-line grocer site with next day delivery in Melbourne and
Sydney. http://www2.woolworthsonline.com.au/
Woolworths has 7 national distribution centres supported by smaller facilities:
NSW – Warnervale (2259) 54,533m2; Yennora (2161) 74,000m2; Minchinbury (2770)
80,000m2; Erskine Park (2759) ambient & liquor 51,830m2 handling 30,000 pallets
and with 60 docks.
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QLD – Murarrie (4172) 187,058m3 chilled/frozen operated by Americold; Bohle (4818);
Churchill (4305); Acacia Ridge (4110); Stapylton (4207) liquor 22,000m2; Larapinta
(4110) ambient & refrigerated 72,000m2; Fishermans Islands (4178).
VIC – Broadmeadows (3047) 48,000m2; Laverton North (3026) ambient, liquor
70,500m2; Mulgrave (3170) 70,000m2; Barnawartha (3691) 80,000m2; Somerton
(3062) 70,000m2
WA- Spearwood (6163) frozen; Perth International Airport (6105) 34,000m2 multitemperature; Bunbury (6230) 4,000m2/2,000 pallet chilled meat
SA – Dry Creek (5094) x 2 frozen; Gepps Cross (5094)
TAS – East Devonport (7310); Breadalbane (7258) meat; Western Junction (7212).
Kerry Logistics, headquartered in Hong Kong, won the contract to supply landside logistics
and supermarket general merchandise for southern Australia in 2012. Kerry is a major
F&B 3PL supplying omni-channel markets in China. Kerry owns and operates an
intermodal terminal and container park in Gillman (SA) and Melbourne (VIC) and a cold
chain logistics warehouse in Maidstone. The intermodal operations handle wine, auto and
FMCG.
ALDI
ALDI has 300 stores in Eastern Australia. ALDI’s logistics model is an integrated regional
model, with one regional management of stores, warehousing and distribution/transport
for around 100 stores.
The warehouses are large and multi-temperature. In recent years, ALDI has spread from
the Eastern States to WA and SA. A new warehouse is being built in Jandakot (WA) to
open in 2016, on a 13.5 hectare site with a warehouse of 48,000m2. In SA, the DC is
30,000m2 located at Regency Park.
VIC - Dandenong 56,000m2; Derrimut 43,000m2 ;
NSW - Prestons 36,213m2; Minchinbury 40,000m2 with a 5,400m2 cold storage annexe
and 3,000m2 office;
QLD - Staplyton 53,000m2
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METCASH
Metcash services 2,400 outlets; 1,365 IGA stores, 117 Foodland stores, 484 FoodWorks
stores, 245 Lucky 7 convenience stores, 18 Campbells Cash & Carry warehouses; and CStore – a bulk sales outlet which services route trade and foodservice. Metcash also has
Australian Liquor Marketers, with 1,700 outlets including Harry Brown, Sip n Save,
Western Cellars, Liquor legends, Urban Cellars, Thirsty Camel (140 outlets). Metcash also
supplies Independent Brands – Cellarbrations, IGA Liquor, Bottle O, Bottle O
Neighbourhood. Metcash also exports from its QLD warehouse, over 800 brands to Asia
Pacific countries. Major Metcash distribution centres are located at –
NSW – Huntingwood 82,853m2 (2148); Macquarie Park (2113)
VIC – Laverton North (3026)
QLD – Crestmead 103,000m2 (4132)
SA – Kidman Park (5025)
WA - Canning Vale 100,000m2 (6155)
COSTCO
The membership club cash and carry warehouse model of food retailing is predicated on
a supply chain model of “full pallet/container in - full pallet out direct to store”, to limit the
number of “handprints” on the product.1 Rather than warehousing, a Costco Depot is a
cross-docking facility, which consolidates pallets and re-routes them to the store
warehouses. The product spends under 24 hours in the facility. Costco is expanding its
current 6 outlets to Moorabbin Airport and Epping in VIC, Kilburn in SA. Each
“warehouse” outlet has a footprint of around 14,000m2.
SPAR
An international FMCG retail franchise with 100 outlets in Australia across QLD, NSW,
ACT and NT. SPAR has a DC located in Acacia Ridge (4110) of 40,000m2 and leases
space for 2,500 chilled and frozen SKUs through Costa Logistics in Morningside (4170) in
QLD.
1
Wulfraat, M., “The Secret to Costco’s Success Lies in Supply Chain Efficiency”, May 12, 2014 in www.canadiangrocer.com
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3.
MULTI-USER WAREHOUSING
These facilities enable a number of clients to store product and to commonly gain
advantages in tailored storage solutions, use intermittent overflow storage space and coloading savings in delivery.
Major supply chain and logistics suppliers including Linfox, Toll, DHL, StarTrack, offer
integrated storage, warehousing and distribution services to food companies. The storage
is food quality, multi-temperature and supported by state-of-the-art warehouse
management systems and distribution networks with global reach.
The benefit of leasing from a 3PL supplier is largely in the mix of arrangements available.
Companies can lease a set space, or an entire warehouse; or choose a mix of a fixed
amount with variable pay-as-you-use space for seasonal and overflow periods. This
avoids overheads and enables a level of tailoring of space. Other benefits include
serviced office space and meeting rooms; stock visibility and security and reporting on
stock movements and individualised KPIs.
A typical warehouse profile for the major 3PL is the new Linfox facility in Kewdale, WA.
This warehouse of 80,000m2 is both a distribution centre and multi-user warehouse which
can hold 25,000 pallets in a temperature controlled environment, with a high security
area capable of handling prescribed goods such as alcohol and pharmaceuticals. It has
overflow/peak season storage, cross-docking, and is linked with rail. This format is highly
sought after, as 3PL suppliers seek to optimise spaces they lease and in turn drive down
costs for customers.
High demand sites for this form of warehousing are on the periphery of major urban
areas, eg: Minchinbury; Prestons (NSW), Edinburgh Parks (SA); Derrimut (VIC).
3PL warehousing is now worth $100 billion in revenue in Australia (IBISWorld 2013) and
is growing at 3% per annum. While food grade warehousing is a subset of this activity, it is
a significant investment in the food value chain. Suppliers such as Goodman, Australand,
DEXUS, GPT and Charter Hall report strong demand for this large format warehousing.
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Sectors driving demand for industrial properties in 2013-14
Despite subdued economic conditions in recent years, demand for large format
warehousing properties is high. This demand for warehousing is being driven by a number
of factors, including three key considerations –
•
The growth of imported products, estimated at 5.8% per annum 2014-2023 (Deloitte
Access Economics);
•
3PL suppliers and manufacturers seeking strategic locations for warehousing on outer
city fringes with good arterial road and rail access to save on transport costs; and
•
A need for scope to increase automation of warehousing systems to decrease labour
costs
Findings from the Australian Food and Grocery Council survey of route trade in 2012
indicated that cost savings in this segment could be gained by further consolidation of 3PL
suppliers. Food companies in this segment typically have up to 5 3PL providers and 60%
retain their own delivery fleet. Collaboration to increase order size and drop density
through 3PL consolidation is expected to reduce costs.
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4.
FOOD DISTRIBUTION STORAGE
These are generally smaller scale storage facilities with multi-brand collections for
distribution in a specified geography or service segment. There are a myriad of
foodservice, convenience and route trade suppliers operating storage sized between
400m2 and 5,000m2, usually with cool rooms and freezer bays.
Food distributor examples:Bidvest is the largest foodservice supplier servicing fast food restaurants, major hospitality
outlets. The company has developed Australia Independent Vendors (AIV) which supplies
food from 30 distributors to smaller outlets such as school canteens and route trade.
www.bidvest.com.au
Combined Foodservices Australia (12 members servicing 33,000 outlets)
www.combinedfoods.com.au
Countrywide (100+ members) covering a wide range of food outlets and foodservice
www.countrywide.net.au
NAFDA (60 distribution centres servicing 53,000 outlets)
www.nafda.com.au
Superior Food Services
This distributor operates 7 warehouses on the East Coast of Australia, each around
5,000m2 www.superiorfs.com.au
Warehousing is operated in numerous locations across the country by major caterers such
as Spotless; Sodexo; ISS; Transfield; Programmed; UGL; Compass and Delaware. These
companies offer a range of food and catering products to remote mining sites; defence
and institutional settings; convenience outlets such as service stations and major sporting
and recreational venues such as stadiums and conference centres. Catering is embedded
in a wider service offering including cleaning, laundry and building maintenance. A
significant proportion of storage space is leased from 3PL operators. For example,
Spotless leases 98 properties with warehouses across Australia.
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5.
E-FULFILMENT WAREHOUSES
These are an emerging model of warehousing which are associated with on-line grocery
stores and e-commerce models. While largely servicing ambient product at this stage, they
are expected to emerge as multi-temperature storage facilities servicing major urban
areas. Major e-fulfilment centres – 50,000m2 plus, used to bypass DCs and deliver direct
to retailer, sortation centre or consumer.
It is anticipated that across major population centres, the trend of on-line grocery and
meal delivery services will escalate as it has in the US, EU and Asia. This model requires a
specific storage and distribution model focused on fresh produce, multi-temperature, short
term storage. Outlets for customer pick ups are convenience stores (note Woolworths and
Coles are investing in these in inner city areas) and route trade as well as in-home
delivery.
On-line Grocers examples:
www.shop.coles.com.au
www.myfoodbag.com.au
www.farmhousedirect.com.au
www.groceryshop.com.au
www.saveonbrands.com.au
www.pantrypacker.com.au
www.aussiefarmers.com.au
On-line meal deliveries examples:
www.menulog.com.au
www.dishd.com.au
www.gourmetdinnerservice.com.au
www.bodyandsoule.com.au
www.choicefreshmeals.com.au
www.deliveryhero.com.au
www.fresh2u.com.au
www.dietlicious.com.au
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www.myasiangrocer.com.au
www.exoticgroceries.com.au
www.hellofresh.com.au
www.woolworthsonline.com.au
www.groceryrun.com.au
www.grocerybutler.com.au
6.
SUMMARY OF FINDINGS
Key trends in food warehousing and storage indicated in the collation of this data are:
1. The increasing use of 3PL suppliers.
2. A shift from one single contract 3PL supplier to several by major supermarket chains,
reflecting more complex global procurement and more complex consumer demand
patterns.
3. Multi-client composite warehousing solutions in large formats to deliver cost
efficiencies and improved service levels through investment in warehouse
management systems and transport articulation.
4. Consumer on-line grocery and prepared food delivery is growing from a low base
and will create food e-fulfilment centre demand, with a need for multi-temperature,
multi-user 3PL sites capable of delivering to convenience stores, route trade and local
supermarket outlets as well as consumer homes.
5. The wholesaler is bypassed and the granularity of the supply chain is polarised to
large format storage and small, consumer-focused delivery options.
6. An increasing number of large format 3PL investments are being made in railconnected locations, providing the option of intermodal transport.
7. A significant number of food suppliers are becoming importers and suppliers of
storage capacity, having invested in this capacity initially for their own needs.
8. Sizeable cost savings are available to food manufacturers and producers through
collaborative 3PL warehousing, storage and delivery services.
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APPENDICES
A
Food grade warehousing by postcode
B
Emerging new types of logistics facilities
C
Article: “Insight: emerging technology and changing consumer
interface” AFGC, 2014.
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QUEENSLAND FOOD GRADE STORAGE
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BRISBANE FOOD GRADE STORAGE
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NORTHERN TERRITORY FOOD GRADE STORAGE
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WESTERN AUSTRALIA FOOD GRADE STORAGE
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PERTH FOOD GRADE STORAGE
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ADELAIDE FOOD GRADE STORAGE
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MELBOURNE FOOD GRADE STORAGE
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TASMANIA FOOD GRADE STORAGE
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NSW EAST COAST FOOD GRADE STORAGE
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SYDNEY FOOD GRADE STORAGE
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Appendix B
Source: ISCL based on JLL e-Commerce Impact on Retail Logistics, 2013
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Appendix C
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GLOSSARY
Third party logistics (3PL) and fourth party logistics/lead logistics (4PL) provider services
Source: Council of Supply Chain Management Professionals (CSCMP), 2010
Break bulk
A shipping term indicating the product is not containerised or shipped as a
dry or liquid bulk form. Generally it refers to products such as timber, steel. However, it
also refers to the unpacking of groupage or FAK shipments.
BBD
Best before date
Bulk storage Bulk or block storage is
Container load/unload
Also called container stuffing/de-stuffing, stripping or in the
case of domestic rail containers, devanning, this term refers to the removal or loading of
goods to or from the container and the receipting of the goods for the customer in
preparation for delivery or storage. There are businesses skilled in rapid
loading/unloading of containers that will supply a mobile team.
Composite Distribution Centres
Composite distribution centres have a range of
temperature zones for storage of diverse food products
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Cross Docking This terms refers to the receipt of cartons or pallets from suppliers at the
dock of the warehouse. They are then loaded for distribution on transport within a 24
hour timespan for delivery to a distribution centre or they may be blended with other
cartons or pallets for delivery to a retail outlet/s in one geographic area. Cross docking
enables the transport to be optimised and the products to be brought closer to the
distribution market. Often the products are pre-assembled in store-ready pallets, which
minimises the labour required to assemble outward pallets and the use of storage space
at the warehouse.
DC
Distribution Centre. A facility in which product from multiple suppliers is blended to
the specification of retail outlets or internal business units. Kenneth B. Ackerman in
“Words of Warehousing” defines a DC as a “facility from which wholesale and retail
orders are filled”, adding that "the term is used to describe a high-velocity operation as
opposed to a static storage warehouse." It is customer-focused, driven by technology,
offers value-added services and is dependent on relationships between suppliers and
customers. It is a key link in the value chain of the product.
EDI
Electronic data interchange, a data communications system to facilitate exchange
between customer’s and logistics supplier’s own enterprise resource planning system.
FAK Freight all Kinds. This term refers to a container or ULD assembled from goods
from multiple suppliers for shipment.
FIFO First in: first out stock rotation
FMCG Fast moving consumer goods
Groupage An alternate term for a consolidation shipment model, where shippers with
less-than-a-container-load share the shipping container.
LCL/FCL
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Less than a container load; full container load
Pick and pack
Picking refers to the assembly of products in the warehouse in
preparation for delivery. Picking systems include “pick to light” using LED lighting; “voice
picking” via headsets instructing pickers; and “pick to cart” mobile batch picking, sorting
and packing are combined.
Proof of Delivery (POD)
Proof of Delivery is generally a signed letter or receipt
verifying the goods have arrived at the depot or warehouse in fit condition and in full.
Electronic PODs now enable customers to go online and check their goods, enabling the
subsequent financial transactions to proceed while the goods are in storage or being
distributed.
Racked storage
Racking is a warehouse storage system generally designed for
pallets or “skids”. Some racking is also designed for cartons. Racking enables products to
be stored on multiple levels and increases the density and capacity of warehousing.
Route trade Route trade refers to corner stores and cafes. While route trade is a small
segment in the overall food supply chain, it is a significant outlet for beverages.
Scanning
Radio frequency (RF) scanning enables real time confirmation of movement
of bar coded items, cartons and pallets in a warehouse, eliminating paper recording. Use
of RF scanning eliminates errors in picking products, direct control over actions relating to
stock and the ability to track and trace movement of the product.
Security
Warehouse security systems include back to base alarms which notify the
monitoring station or the mobile security personnel if a breach has occurred. CCTV
monitoring is also used in warehouses. Warehouses also have electronic keyed access to
control all out of hours deliveries and entry. Additional security is supplied by locked
secure areas for prescribed goods such as alcohol and pharmaceuticals, or as required by
the Customs Licence that applies to bonded warehousing.
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