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Case Study: Pepsi-Cola Bottling Company of Central Virginia

Business Challenges

• Pepsi's existing operation in Warrenton, VA was entirely manual. Labor costs were rising while employee turnover rates were very high.
• The US beverage industry as a whole is experiencing an increasing number of SKU’s.
• Fuel costs are continuing to increase for mixed pallet delivery.
• Customers are demanding increased delivery accuracy.

Key Technology

• Automated Case Flow Module with 140 roller lanes utilizing motorized drive rollers and gravity conveyor
• TGW mini-load AS/RS for lower velocity SKU’s
• T-Tek Automated Palletizer
• WulfTec Stretch Wrapper
• Exacta Human Machine Interface (HMI) Software
• Panasonic Camera System and DVR
• Mettler-Toledo ExpressWeigh Scale and Banner Height Check

Results

• The system handles over 350 SKU's while producing mixed pallets at 1500-2000 cases per hour.
• The amount of labor required to process orders was decreased by two thirds.
• The system has greatly reduced damaged goods.
• The system allows Pepsi Central Virginia to be ASN (Advanced Shipping Notice) compatible.
• The system allows Pepsi to meet the demands of their customers with greater accuracy, quality, and shorter order cycle times.