Global Material Handling System Integrators

Mixed Pallet Building with Automated Case Flow Reduces Labor and Increases Accuracy (2000 cases/hour) at Pepsi


Pepsi Central Virginia is a distributor that celebrated 100 years of service in June of 2008. Pepsi's existing operation in Warrenton, VA were 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, and customers are demanding increased delivery accuracy. Bastian Material Handling provided the following technologies to Pepsi Central Virginia: 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 Wulf-Tek Stretch Wrapper Exacta Human Machine Interface Software Panasonic Camera System and DVR Mettler-Toledo ExpressWeigh Scale and Banner Height Check The system now produces mixed pallets at 1500-2000 cases per hour. The amount of labor required to process orders was decreased by two thirds. The system allows Pepsi to meet the demands of their customers with greater accuracy, quality, and shorter order cycle times. To view the case study for Pepsi Central Virginia click here.

Author: Margie Schramke


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