The new highly automated distribution centre for Bausch + Lomb in Aalsmeer is rapidly taking shape. After two decades, the existing site close to the Schiphol Airport no longer met modern operational requirements. How can an organisation respond to changing order flows, rising customer expectations and ageing technology? This project demonstrates what a future-ready logistics strategy looks like.
From Operational Limits to a Future Vision
Bausch + Lomb’s existing intralogistics system was increasingly reaching its limits. Automation had become outdated, order structures had changed, and customers expected faster and more flexible service. It became clear that improving the current facility would no longer be enough.
A new distribution centre created the opportunity to redesign operations from the ground up, with greater capacity, faster processing speeds and room for future growth. At the same time, standards remained high. With a broad portfolio of medical and optical products, quality control and traceability are essential.
According to project lead Pieter de Jong, one key question shaped the development: how do we create a solution that works today while remaining ready for tomorrow?
Clear Requirements from the Start
It quickly became clear that retrofitting the existing system was not a viable option. The decision was therefore made to develop a new facility. The requirements were ambitious but clear:
- Higher processing capacity and increased daily order line volumes
- Flexibility to respond to future market changes
- Greater automation with lower operational costs
- A sustainable building with BREEAM certification
- Sufficient power supply and available space
- Retention of the current geographic location
The final point was particularly important. The Dutch site combines both distribution and sales functions, bringing operational and office teams together in one location. Maintaining that integrated structure was therefore essential.
Choosing the Right Automation Partner
Following an extensive planning and analysis phase, the search began for an automation partner. Two suppliers were shortlisted, each producing a detailed end-to-end design. TGW Logistics was ultimately selected.
The decision was based not only on the technical solution and budget, but also on the quality of collaboration.
The proposed systems closely matched operational needs, with strong attention to ergonomics, maintenance, and scalability. Cultural fit also proved important, with mutual understanding and a shared approach creating confidence in a long-term partnership.
Shuttle System at the Core of the Operation
The new distribution centre is powered by a large-scale shuttle system with more than 135,000 storage locations. This can be expanded to 150,000 locations, with an additional 30,000 available in a later phase. Double-deep storage ensures maximum use of available space.
Around 300 robots handle tote storage and retrieval, with a capacity of up to 8,700 movements per hour. Orders are processed through ergonomic goods-to-person workstations equipped with light pointers, improving both speed and accuracy.
The move to a single goods-to-person picking system represents one of the most significant changes. Where several systems previously operated side by side, activities will now be managed from one fully integrated zone.
Automation also plays a major role in the packing area. Cartons are automatically erected, sealed and cut to size. This reduces shipping volume and lowers transport costs. A second shuttle warehouse acts as a buffer, after which automated palletising ensures efficient flow through to dispatch.
There is also a strong focus on detail and traceability. Every serial number is linked to the customer order, supported by automatic documentation and labelling. This is critical in a sector where accuracy and compliance are essential.
Smarter Working Through Automation
The move to a new automated distribution centre does not mean replacing people, but changing roles and processes. Robots and shuttle systems take over repetitive tasks, while employees focus on control, supervision and continuous improvement.
To ensure a smooth transition, change management has been a major priority. Through town halls, presentations and site visits, employees have been involved from the beginning. More than 250 team members gained early insight into the design and project progress.
The physical changes are visible, new workstations and more goods-to-person solutions, but the core of the work remains familiar. That continuity helps make the transition manageable.
Ready for Further Robotics Integration
Although robots already play a key role, the new design leaves room for further automation. Dedicated zones have been included so that future robotic applications can be integrated with ease.
This may include automated picking for small orders or additional internal transport solutions. For now, Bausch + Lomb is taking a phased approach: first stability and performance, then further optimisation.
Go-Live Planned for 2027
The next phase of the project will focus on completion and testing. Infrastructure and IT systems will be finalised in 2026, followed by commissioning and trial runs. The planned go-live date is 2027.
From this location, customers across Europe will be supplied, with exports also reaching the Middle East and Africa. The centre will also serve as a link between Bausch + Lomb’s other international distribution hubs.
Confidence in the Future
The new distribution centre is more than a logistics project. It is a strategic investment in flexibility, quality and scalability.
“With this project, we will be able to serve our customers even better,” concludes Pieter de Jong. “I am fully committed to making that happen. We are genuinely building for the future.”
TGW Logistics is a foundation-owned enterprise headquartered in Austria and a global leader in warehouse automation and warehouse logistics. As a trusted systems integrator with more than 50 years of experience, we provide end-to-end services: designing, implementing, and maintaining fulfilment centres powered by mechatronics, robotics, and advanced software solutions.
With over 4,600 employees across Europe, Asia, and North America, we combine expertise, innovation, and a customer-centric dedication to help keep your business growing. With TGW Logistics, it's possible to transform your warehouse logistics into a competitive advantage.
