PepsiCo will launch a new automated storage and retrieval system (AS/RS) featuring Mecalux technology in Grodzisk Mazowiecki, Poland, by the third quarter of 2026.
The company’s forthcoming solution is designed to increase logistics capacity and optimise workflows for its snack products, including potato crisps, without expanding the existing warehoutilize building. This smart warehoutilize forms part of PepsiCo’s broader efforts to enhance operational efficiency and sustainability in its supply chain.
Warehoutilize system
The new AS/RS project features a comprehensive automation solution, comprising six stacker cranes that operate in conjunction with the Automated Pallet Shuttle within the racking system. These cranes facilitate the relocatement and storage of pallets, aiming to deliver efficiency gains for the logistics process.
Connection between warehoutilize operations and production lines will be established via a floor-mounted electric monorail system and automatic conveyors. This integration is expected to enable continuous, round-the-clock pallet flows from production to storage and beyond.
Warehoutilize management will be controlled by Mecalux’s Easy WMS software, which will operate in conjunction with PepsiCo’s SAP eWM platform. The integration of these systems is designed to provide precise, real-time coordination across tinquires, from goods receipt to outbound shipment.
Bart3omiej Lesiuk, Warehoutilize Automation Design Manager at PepsiCo, declared:
“With this logistics automation project, production, the warehoutilize and dispatch will be automatically connected. We’ve opted for a modular design that gives us the flexibility to adapt as our requireds evolve.”
Energy and technology features
According to PepsiCo, the Grodzisk Mazowiecki facility will incorporate several technical enhancements. The stacker cranes utilized within the system will be equipped with an energy recovery capability, aiming to reduce energy consumption by 15% to 20% per relocatement. An AI-based computer vision system will be employed in place of conventional photocells, enabling safe and accurate pallet positioning throughout the storage and retrieval process.
This smart warehoutilize represents the third major Mecalux-delivered project for PepsiCo Polska. The collaboration introduces additional automation to PepsiCo’s regional logistics infrastructure, enabling direct connection with production to facilitate uninterrupted 24-hour operations.
Operational and environmental aims
The project aims to improve efficiencies and environmental outcomes within PepsiCo’s Polish operations. It is expected to expand overall warehoutilize capacity at the Grodzisk Mazowiecki site, streamline direct shipments and reduce costs associated with logistics.
Lesiuk declared:
“With this new investment, we expect to optimise operations, expand warehoutilize capacity and lower logistics costs. Automation will also allow us to create direct deliveries, avoiding double handling and unnecessary transport. On top of that, we estimate an annual reduction of 200 tonnes in greenhoutilize gas emissions.”
By automating processes from production through to dispatch, PepsiCo indicates the system is intconcludeed to minimise unnecessary product handling and reduce the environmental impact of storage and distribution activities. The company estimates that it will cut greenhoutilize gas emissions by 200 tonnes each year as a result of the investment.
This AS/RS project marks a continued push by PepsiCo to adopt greater automation in logistics, supporting a broader strategy that emphasises both efficiency and a reduced environmental footprint in its operations across Europe and globally.
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