PepsiCo was looking for a way to improve its end-to-end operations, starting from managing incoming inventory to efficient storage and dispatch to different distributors. The main aim was to increase storage and throughput capacity, optimise operations within a limited space, and set up a direct dispatch system to distributors.
To tackle this challenge, PepsiCo needed an automated mixed case palletizing solution with a large number of storage bins and pick faces for efficient case picking. The solution also had to allow for manual case picking to create mixed pallets. The innovative solution provided by Addverb not only met these requirements but also automated the manual case-picking process, leading to further improvements in operational efficiency.
Addverb conducted an in-depth study by visiting manually operated sites and engaging extensively with stakeholders at all levels, from factory operators to senior leadership. Addverb’s solutions team collaborated closely with PepsiCo to design an innovative warehouse solution, incorporating crane-based Automated Storage and Retrieval Systems (ASRS), Mother-Child Shuttles, and Pick-by-Light technology. These systems were seamlessly integrated and powered by our advanced Warehouse Control System (WCS).
A standout feature of the solution was the modification of the Dense Racking System, creating custom aisles for the formation of Rainbow Pallets (mixed case palletizing). This allowed for dynamic allocation of pick faces, significantly improving throughput for both picking and put-away operations. The entire mixed case palletizing automated solution was implemented within a compact 36,000 sq. ft. facility.
The solution provided by Addverb is one of the most unique mixed case palletizing solutions as it utilises the Mother-Child shuttle system not only for storage and retrieval but also for Rainbow-Pallet formation at the base of the same dense racking.
Low-Bay Storage systems consisted of G+4 levels, with 3,500 pallet storage positions.
The high bay area and low bay area were interconnected via mezzanine.
2 Crane-based ASRS were installed for the high bay area for slow moving SKUs.
At the 'G' level, a single mother shuttle transferred to 6 single-deep mother-child shuttle systems for sorting and pallet formation.
4 Mother-Child shuttle systems were deployed on upper 4 levels,comprising a total of 11 mother shuttles, 10 child shuttles, and supporting systems.
The double and triple deep ASRS cranes can access high bay area of up to 30m, with 6200 pallet positions
Achieved system throughput of 300 pallets/hour.
Our extensive product portfolio helps us design customised solutions for varying industry requirements.
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