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Pepsi refreshes logistics for mixed pallets

Article-Pepsi refreshes logistics for mixed pallets

Pepsi refreshes logistics for mixed pallets
3. The Mixed Layer Pick (MXLP) system forms and builds layers of mixed SKU by like-package type cases, at a rate of about 33 cases/min, more than five times the manual pick rates of PBC’s traditional warehouses.

Company: Pepsi Beverages Co. (PBC)
Headquarters: Somers, NY
Plant location: Tampa, FL
Product(s): Ready-to-drink beverages (carbonated soft drinks, bottled water, juices/juice drinks, teas)
Packages handled: PET bottles, aluminum cans, multipack cartons, trays
Operations: Palletizing; in-plant handling/warehousing; shipping
Sq ft: 47,950 (warehouse space)


Pepsi Beverages Co. (PBC) has finished the second phase of a warehouse addition to its bottling plant in Tampa, FL, and has installed palletizing equipment and warehouse handling systems. 

A warehouse control system (WCS) handles two storage/retrieval machines of the automated storage and retrieval system (AS/RS), conveying systems for pallets and cases, five robots for layer picking/palletizing, pallet squaring stations, stretch wrapping, print-and-apply labeling and the integration of the WCS to PBC's existing enterprise resource planning and warehouse management system (ERP/WMS). (See a video at

The systems, from Westfalia Technologies Inc. (, help PBC meet its commitment to the waste reduction principles of Six Sigma. This compact warehouse uses only 30 percent of the footprint of a conventional facility. PBC has realized significant financial benefits through the efficient design of the AS/RS system, which maximizes storage space and minimizes operating costs (less energy and waste). Additionally, inventory is more accurate through Westfalia's Savanna.NET WCS. 

The AS/RS meets PBC's need for maximum storage and high throughput. It also provides a buffer to handle peak production from its bottling plant and helps prepare various types of pallets for shipment to customers.
Stretch wrappers are supplied by Lantech (, print-and-apply labelers from Diagraph ( and conveyors from Westfalia.

Pepsi Beverages Co., based in Somers, NY, is the largest manufacturer, seller and distributor of Pepsi beverages, with more than 100 plants worldwide and 545 distribution centers. Among the brands it handles are Pepsi, Aquafina, Aqua Minerale, Tropicana, Lipton Iced Tea, Starbucks Frappuccino, Dole juices, Mountain Dew, Sierra Mist and the SoBe line of beverages.


Pepsi Beverage Co. crane T car

Pepsi Beverage Co. gantry

Pepsi Beverage Co. mixed-layer robot

Pepsi Beverage Co. Savanna screen shot

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