PepsiCo Polska plans to open a new automated storage and retrieval system (AS/RS) in Grodzisk Mazowiecki, Poland, with Mecalux technology.
Connected to the production area, the solution will accommodate potato crisps and other snacks. It was designed to increase PepsiCo’s logistics capacity and optimise workflows without expanding the existing building.
The project involves implementing a comprehensive solution. It features six stacker cranes serving racking equipped with the Automated Pallet Shuttle.
A floor-mounted electric monorail system and automatic conveyors will link the warehouse with the production lines, enabling a continuous, round-the-clock pallet inflow.
AS/RS operations will be overseen intelligently by Mecalux’s Easy WMS warehouse management system, which will be integrated with PepsiCo’s SAP eWM software. This two-way connection will precisely coordinate all logistics processes, from goods receipt to outbound shipments.
“With this logistics automation project, production, the warehouse and dispatch will be automatically connected,” says Bartomiej Lesiuk, warehouse automation design manager at PepsiCo. “We’ve opted for a modular design that gives us the flexibility to adapt as our needs evolve.”
This new AS/RS will be the third warehouse project Mecalux has delivered for PepsiCo Polska. In addition to its link with production and 24-hour operation, the Grodzisk Mazowiecki facility features several key tech innovations.
The stacker cranes are equipped with an energy recovery system, saving between 15 percent and 20 percent in energy consumption with every movement.
They also incorporate an AI-powered computer vision system instead of traditional photocells, ensuring safe, accurate pallet positioning.
“With this new investment, we expect to optimise operations, expand warehouse capacity and lower logistics costs,” says Lesiuk.
“Automation will also allow us to make direct deliveries, avoiding double handling and unnecessary transport. On top of that, we estimate an annual reduction of 200 tonnes in greenhouse gas emissions.”
