Whether it’s clothing, consumer goods, or food, TGW Logistics ensures that goods arrive where they’re supposed to. The Austrian intralogistics specialist manufactures mechatronics and robotics at its site in Marchtrenk. These include steel structure and conveyor technology components for logistics and material flow systems used by global companies like Adidas and Zalando. The welding used in production is characterized by a wide variety of component variants, small batch sizes, and short lead times. At the same time, the shortage of skilled workers is making the overall situation more challenging. To ensure production remains flexible and reliable in spite of this, TGW Logistics uses the CWC-D cobot welding cell from Fronius.

The welding tasks at TGW Logistics are carried out on a wide range of components, from those just a few centimeters in size to large-format parts with side lengths of up to two meters, and everything in between. Steel is the primary material processed, mainly S235 grade with some S355 as well. Typical components include fall arrest brakes, angle brackets, gusset plates, and load-bearing support feet, often produced in recurring runs of between 10 and 200 pieces. However, the actual number of types is significantly higher.

Manual welding previously limited output

Until recently, many of these components were welded by hand, which was no small feat given the wide variety of geometries, weld layers, and material thicknesses. Without automated support, highly qualified welding specialists must regularly assist welders whenever more complex weld seams require special attention. While this ensures welding quality, it ties up valuable capacity; especially in a manufacturing environment like TGW Logistics, where welders often have to respond to changing requirements on short notice.

At the same time, the shortage of skilled workers is becoming increasingly severe. Traditional manual welding jobs are becoming less attractive to many young skilled workers, while positions in the fields of CNC technology and robotics are in much higher demand. These days, spending an entire workday in a welding booth appeals to fewer and fewer people.

“Our welders often have to weld the same corner weld 100 or 200 times,” says Mario Beidinger, Manufacturing Manager at TGW Logistics. “What at first seems like a routine task requires intense concentration for hours on end, which eventually wanes. Nevertheless, we need to be able to rely on consistently high welding quality regardless of who is guiding the torch.” However, according to Beidinger, this is a challenge in practice: “Every welder works a little differently. One welds faster at a higher current; the other welds slower with fewer amps. This makes even weld seams of consistent quality the exception rather than the rule—and that’s exactly what we wanted to change.”

Against this backdrop, TGW Logistics was looking for a solution that would reduce the team’s workload and ensure reproducible results in accordance with established standards. At the same time, they wanted to significantly improve welding speed and process stability.

Why TGW Logistics now relies on automated welding

In addition to the desire to boost productivity, the company had three other crucial requirements: consistently high quality, reduced reliance on available skilled workers, and the flexibility to handle a wide variety of components.

Following an internal evaluation phase, which confirmed the Fronius system’s compatibility with the existing production process, Beidinger’s team opted for the CWC-D. The cobot welding cell is specifically designed for small and medium batch sizes. Its stand-out features include its flexibility, user-friendly operation, and ability to perform parallel processes without any breaks in operation.

CWC-D: one cell and two stations for minimal downtime

At the heart of the welding solution is the two-station concept, which allows welding and setup to be carried out in parallel. While welding is taking place at one station, the second one can be set up. This significantly reduces downtime and increases output.

Each station provides a work area measuring 1,500 × 1,000 × 600 mm and is designed to handle components weighing up to 2,000 kg. The partition wall can be removed in a few simple steps to accommodate particularly long components, creating a continuous 3,000-mm-long work surface. This is ideal for bulky structures or assemblies that previously required a lot of effort to position.

Effective accessibility thanks to an integrated longitudinal axis

The cobot is mounted on a mobile longitudinal axis that is fully integrated into the cobot control. This means two operating modes are available: the cobot can either incorporate the axis directly into the welding movement as an additional degree of freedom, or it can be positioned as desired along the rail. As a result, TGW Logistics does not need a positioner or rotary table; the components are secured to the welding table and welded in a single pass.

Intuitive programming in three steps

The CWC-D is intentionally designed to be easy to use. Welding programs are created at the cell itself using the ‘teach-in’ method and follow a clearly structured sequence:

1. Define movement points on the teach panel.
2. Teach the start, welding, and end points on the torch. The torch is guided from point to point, and each point is saved at the touch of a button.
3. Select a predefined welding job on the teach panel (identified by material, sheet thickness, and weld seam type).

The drag-and-drop interface is designed so that even employees with little experience can quickly get to work. At TGW Logistics, an apprentice with a welding qualification operates the system independently; one example that demonstrates just how intuitive the system is to use. Compared to traditional welding robots (which typically require specialized personnel to program them), this gives employers greater flexibility in deploying their staff.

CE-certified safety at all times

Automatic safety doors, extraction hoods, UV protection, and the cell’s enclosure ensure that welding fume is reliably extracted and arc radiation effectively shielded. The entire cell complies with the Machinery Directive 2006/42/EC and is CE-certified—a key consideration for TGW, where welding technology is closely integrated into existing production processes.

Flexible welding processes depending on the component

The Fronius TPS/i 400 CMT welding machine, integrated into the cobot welding cell, provides TGW Logistics with a wide range of welding processes. The relevant welding procedure specification (WPS) states when each process should be used. It defines the process parameters based on factors like the base material, component geometry, wall thickness, weld seam profile, and required energy input. The specifications are prepared internally and approved by the welding supervisor and contain welding jobs with easily identifiable names.

“We classify the jobs by material and weld seam size; for example, steel plate, 3 mm, A3 weld seam,” explains Beidinger. “Technical specifications alone, such as the amperage, say little about what a job is actually intended for.”

This clear classification ensures that approved welding processes can be uniquely identified and reproduced at any time, as well as reducing operator-induced variations while ensuring process reliability and repeatability throughout the entire joining process.

Proven arcs for the majority of applications

At TGW Logistics, two processes are used for most of the welding tasks:

• Standard MAG arc: 
  A robust, universal process for the majority of steel components with medium to thick walls. Regarded as cost-effective, tried and tested, and stable, it's also the most commonly used process at TGW Logistics. Fillet welds in the horizontal position are primarily produced.
  This process is particularly well-suited for S235—a low-carbon structural steel with good weldability that is predominantly used in manufacturing.
• Pulsed arc:
  A key feature of this process is the controlled droplet detachment achieved by alternating between base current and pulse current. The result is a low-spatter arc across the entire power range, combined with higher welding speeds compared to a standard arc. At TGW Logistics, this process is primarily used for more complex seam geometries and when there are stricter requirements on seam formation. It also provides the necessary process control for the higher-strength S355 steel with an increased carbon equivalent, which is used in some applications.

Additional processes are called on to meet specific requirements:

• CMT (Cold Metal Transfer): 
  The reversing wire movement, with frequencies of up to 170 Hz, produces an exceptionally stable arc with approximately 33% less energy input. At the same time, welding speeds can be almost doubled compared to those of conventional dip transfer arc welding. This process is particularly suitable for thinner sheets, where the influence of heat and distortion are critical factors.
• PMC (Pulse Multi Control): 
  PMC builds on the pulsed arc technology by incorporating adaptive process control with multiple digital stabilizers. These continuously monitor and influence key process parameters, such as arc length, penetration behavior, arc pressure, and ignition characteristics. The result is an extremely stable, low-spatter welding process with uniform seam formation and high repeatability—especially for complex seam geometries.

The individual processes are not always used in isolation; they are also combined to make the most of their respective strengths taking into account the component, seam requirements, and material.

Efficient, reproducible, and flexible processes now prevail at TGW Logistics

When selecting components for the cobot, TGW Logistics follows a clear strategy: only parts that can be fully welded in a single pass are used. “Nothing else makes sense,” explains Beidinger. “Remove any spatter, clean it, touch it up a bit, and it’s ready. Whether I weld individual components ten or two hundred times, once it’s been taught, I get the same result every time.”

The company’s day-to-day work demonstrates just how significantly the CWC-D has transformed its workflows. Many of the recurring components come in several variants, so TGW Logistics now manages approximately 250 pre-programmed welding programs on its network. The actual welding workflow is deliberately kept simple: insert the component, select the program, and press the start button.

TGW Logistics ensures that workpieces of the same type are always clamped in exactly the same position using setup instructions with photos known as ‘photo sheets’. They document both the exact position of the parts on the welding table and the specified clamping sequence, as the order in which the parts are clamped also affects potential distortion. This clearly defines the setup process for the operating personnel so it is reproducible.

While the cobot is welding at station 1, station 2 can already be set up. In addition to the advanced Fronius arc technology, automated torch cleaning also ensures stable welding processes. After a certain number of welding cycles, the Robacta Reamer V automatically cleans the interior of the gas nozzle and applies an even layer of parting fluid to prevent spatter from adhering. This significantly extends the service life of the wear parts. Processes such as CMT or PMC (which produce significantly less spatter) extend cleaning intervals, protect the gas nozzle, and noticeably increase productivity.

If components require a final run in addition to the root pass, TGW Logistics makes strategic use of the cooling time needed between runs. While the first component is cooling, another part is fully welded at the second station. The ‘t₈/₅ time’, as it is known, is determined empirically and stored in the welding program. In practice, however, it has become apparent that separate waiting times can often be eliminated. If there are multiple components on the welding table, the first one will have cooled sufficiently by the time the root weld seam of the last component has been welded. The final run can therefore be completed immediately afterward.

Complex geometries that still require manual welding continue to be handled by experienced specialists. Automation relieves them of repetitive tasks; those that neither make full use of their skills nor are particularly motivating.

Conclusion: a solution that makes TGW Logistics more productive and consistent

In the CWC-D, TGW Logistics has found a welding solution that perfectly meets its specific demands: a wide range of variants, fluctuating production volumes, different geometries. Plus, it addresses a labor market where skilled welders are becoming increasingly scarce. The combination of user-friendly operation, a flexible work area, stable process control, and high repeatability has proven to be a key factor in boosting productivity.

“The investment paid for itself sooner than expected,” Beidinger concludes. “Depending on the application, we now weld 20 to 30 percent faster than we did manually. What’s more, the weld seams are cleaner, there’s less rework required, and significantly less distortion thanks to the controlled heat input. That’s what makes the difference.”

Cobot welding is particularly beneficial for small batch sizes and frequently changing components. A clearly structured combination of a cobot welding cell, a defined WPS, and clearly identifiable jobs makes welding processes readily available, reliably reproducible, and consistent regardless of the operator.

VANCOUVER, B.C. — October 7, 2026 — BC Food & Beverage (BCFB) is advancing plans for the Pacific Gateway Food Terminal (PGFT), a proposed world-class food distribution, processing and innovation hub in Metro Vancouver designed to strengthen Canada’s food security and help Canadian food and agriculture businesses grow.

The proposed terminal would be approximately 750,000 square feet on a site of roughly 50 acres, strategically located near the Port of Vancouver, Vancouver International Airport (YVR), the Fraser Valley and major transportation corridors.

Designed as shared infrastructure for the food supply chain, the PGFT would bring together five key functions: a wholesale market and distribution space connecting BC farmers, producers and processors with retailers, foodservice and other buyers; cold, frozen and ambient warehousing; aggregation and distribution; shared-use processing and packing; and an innovation and commercialization centre supporting small and medium-sized food businesses.

The vision is to create one of Canada’s leading food infrastructure hubs and establish British Columbia as a gateway for food trade, innovation and distribution across Canada and around the world.

“The Pacific Gateway Food Terminal is about building the infrastructure our food system will need for the next generation,” said James Donaldson, CEO of BC Food & Beverage. “British Columbia has extraordinary farmers, food manufacturers, seafood producers and entrepreneurs. This is an opportunity to give them the infrastructure needed to operate and grow at scale while strengthening Canada’s domestic food system.”

BCFB is advancing the project in response to longstanding challenges facing the sector, including fragmented distribution, limited access to appropriately scaled processing and cold storage, transportation inefficiencies, barriers to reaching buyers and the significant cost of scaling food businesses.

The opportunity aligns with the Government of Canada’s National Food Security Strategy and its Food Link Fund, created to strengthen regional food distribution systems and improve the resilience and affordability of Canada’s food supply.

For BCFB, the opportunity goes beyond constructing a single facility. It is about creating a more connected food ecosystem by better linking the businesses, infrastructure and organizations already operating across the province. The PGFT could help create stronger pathways from regional production through processing and distribution to larger domestic and global markets.

The terminal would be designed to complement and strengthen existing infrastructure rather than duplicate it, creating stronger connections among producers, processors, distributors and buyers, as well as regional infrastructure including the BC Food Hub Network.

BCFB is now undertaking industry engagement and feasibility work to ensure the terminal is built around real market needs. Farmers, processors, seafood companies, exporters, independent retailers, distributors and foodservice operators are being asked to identify challenges including cold storage, transportation, processing capacity, access to buyers, distribution costs and export logistics.

The findings will help quantify demand, prioritize services and infrastructure, and shape the business case for the terminal.

The Pacific Gateway Food Terminal represents a significant opportunity to invest in the future of Canada’s food system, strengthening domestic food security while creating the infrastructure Canadian businesses need to grow and compete globally.

British Columbia has the agricultural capacity, manufacturing expertise, entrepreneurs, strategic location and access to global markets to become one of North America’s leading food and agriculture gateways. The Pacific Gateway Food Terminal is intended to help make that possible.

Food & Beverage Manitoba hosted The Totally Awards Gala 2026 on October 7, bringing together chefs, restaurateurs, beverage professionals, and industry leaders to celebrate excellence and innovation in Manitoba’s food and hospitality industries. The evening recognized outstanding achievements in culinary excellence, sustainability, beverage innovation, and customer experience.

Here are some photo highlights from the evening.

Dennis Group, a leading design-build firm dedicated exclusively to the food and beverage industry, will exhibit at PACK EXPO International in Booth 7606 in the Processing Zone, October 18–21, 2026, in Chicago, Illinois. The company will highlight its site search capabilities through demonstrations and share information about its integrated facility planning, design, and construction services.

At Booth 7606, the Dennis Group team will be available to discuss attendees’ site search needs and demonstrate how the company evaluates available properties, including the factors considered during the site search process. Visitors can also learn how Dennis Group supports food and beverage facility projects from planning through startup.

Beyond site search, Dennis Group’s services include conceptual design and master planning, process engineering, packaging system integration, controls and integration, facility design, and construction management. Its multidisciplinary in-house team can deliver full design-build projects or serve as an extension of a client’s engineering team.

In addition to exhibiting, Dennis Group will sponsor and host “Upgrade and Expand Your Facility” on Tuesday, October 20, from 3:00 to 4:30 p.m. in Upper Lakeside. The tour is part of PACK EXPO International’s new Show Floor Discovery Tours program, which offers curated, expert-led experiences to help attendees explore emerging technologies and innovative suppliers across the show floor.

Participation is open to PACK EXPO International attendees who are end users, contract packagers/manufacturers, or retailers. Eligible attendees can reserve their spot during the PACK EXPO International registration process.

For more information about Dennis Group’s site search and facility services, visit Booth 7606 in the Processing Zone or www.dennisgroup.com.