September 14, 2026

Conveyors keep things rolling at Zijderlaan

At logistics service provider Zijderlaan’s distribution centre in Puttershoek, the conveyors set the pace of the day. If one section breaks down, the entire distribution process for packaged sugar comes to a halt. After twelve years of intensive use, this was becoming a problem: there was too much unplanned downtime. So Zijderlaan joined forces with E’Log for a thorough retrofit of its roller and chain conveyors. The work was done section by section, at the company’s own pace. As a result, the system is perfectly reliable again and ready to face the future.

If one conveyor fails, everything stops

The distribution centre revolves entirely around sugar. Packaged sugar products arrive stacked on pallets, directly from the sugar specialities factory, and are stored in the high-bay warehouse. When an order comes in, the products are dispatched to customers in the Netherlands and abroad.

All this inbound and outbound traffic adds up to around 360,000 pallet movements a year and is handled entirely automatically by a network of roller and chain conveyors. All those years of intensive use had taken their toll. Gears, chains and other components that had once operated flawlessly were beginning to wear out. Simple adjustments or lubrication were no longer enough. Moreover, there was insufficient visibility into which components had reached the end of their service life.

This put Zijderlaan’s ability to deliver on its promises to customers at risk. “We operate continuously, 24 hours a day, so we really do depend on reliable components. We have an interconnected chain of conveyors and if one breaks down, everything grinds to a halt. When we realised that the number of defects and unexpected breakdowns was increasing, we decided it was time to take action,” explains Denny Kuijstermans, the company’s logistics manager.

Replacing components without shutting everything down

E’Log had already been responsible for maintaining the system for some time. “Their expertise and professionalism were immediately apparent. They were already familiar with our system and knew exactly what needed to be done,” Denny recalls. “Following a baseline assessment of our system, in which the components were assigned different severity ratings, we drew up a plan together.”

The retrofit programme was tailored to Zijderlaan’s operating schedule, as downtime was simply not an option. For a year, Thursdays were often devoted to the overhaul: the outbound conveyors in the morning and the inbound conveyors in the afternoon. This meant Zijderlaan knew exactly which operations were possible at any given time, while the operational impact was limited to no more than half a day on each occasion.

Ageing often goes unnoticed at first

Zijderlaan’s story illustrates a pattern seen in almost every system. After the usual running-in period for a new installation comes a period of stability, when everything works as it should. But ageing is a gradual process, and its effects tend to become apparent for the first time after about fifteen years. This is when the first components really begin to fail and need replacing. At that point, the installation itself is generally still mechanically sound. It is not until the system reaches around 25 to 30 years of age that the electrical systems begin to falter. Then replacing a few individual components is no longer enough, and it is time to consider a more extensive overhaul.

Zijderlaan had reached precisely this first tipping point and chose to take action before it developed into a problem.

Juggling engineers, parts and working hours

The plan was put into action, with around 50 of the 164 sections undergoing a thorough overhaul. “They often had four engineers working simultaneously to replace gears, chains, rollers and complete housings. This allowed E’Log to work on two sections at a time. Initially, we also worked with larger teams, but that didn’t really work out. You also need to have enough materials available to work in that way. So we scaled things back and decided together that we would continue with smaller teams,” Denny recalls.

“Planning the materials was actually one of our biggest challenges,” adds Arnoud Den Hoedt, E’Log’s country manager for the Netherlands. “A visual inspection allowed us to estimate in advance which materials we would need. However, it was only when our engineers actually opened up a section that they could see exactly what needed replacing. As delivery times can sometimes run to several weeks, we couldn’t wait until then to order the parts. Although we did our best to estimate the required quantities as accurately as possible, we still ended up with slightly more material than we needed.”

Greater peace of mind today, ready for another 15 years

The results can be felt on the warehouse floor. “What I find particularly encouraging is that our own people, who work with the system every day, have commented on how smoothly it is running now. To me, that’s the most important thing,” says Denny.

Taking action in good time has also made the entire operation more predictable. “As an organisation, you want to plan as much as you can. Having everything under control and predictable is ideal for us. A warehouse will probably never be entirely free from disruptions – there could be a lightning strike tomorrow, for example. But whereas something used to crop up every week, it now happens only once every six weeks or so,” Denny explains.

“Looking back, it was primarily the planning and our ongoing communication with E’Log that made this retrofit programme a success,” he continues. “Sometimes two companies are simply a good match for each other. At Zijderlaan, we keep communication direct, remain flexible and respond quickly. E’Log works in exactly the same way.”

Not every challenge calls for an entirely new system. Often, the greatest value lies in what is already in place, provided it receives the attention it needs at the right time. Zijderlaan demonstrated this by recognising the warning signs early and giving its system a new lease of life for the next fifteen years.