Pepsi-Cola Central Virginia

Case Flow and Building Case Study

Business Objectives

  • Reduce labor costs and the high employee turnover rate
  • Accommodate an increasing number of SKUs
  • Improve delivery accuracy for better customer service
  • Capacity to build small format orders by store

Distributor builds mixed pallets at 1,500 cases per hour

Pepsi-Cola of Central Virginia (Pepsi CVA) is a 100-year-old, third-generation family business located in Warrenton, Virginia. The distribution center services 7 counties and ships up to 4 million cases of product each year.

With the installation of an automated order fulfillment system, Pepsi CVA reduced employee overtime, increased shipment accuracy, and created a calmer, more structured facility environment.


Key Technologies

  • Innopick® sorting system with 48 lanes of servo-controlled chain conveyor
  • NedPack Prorunner mk5
  • 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
  • Human Machine Interface (HMI)
  • Panasonic Camera System and DVR
  • Mettler-Toledo ExpressWeigh Scale and Banner Height Check

Stocking Innopick®


See the results

The system handles more than 400 SKUs, 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.


Full Layer Pallets


Photos of our solution

Interested in automated case flow technology?
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