PepsiCo is set to launch a state-of-the-art automated storage and retrieval system (AS/RS) at its Grodzisk Mazowiecki facility in Poland by Q3 2026, utilizing cutting-edge technology from Mecalux. This new installation, connected directly to production lines, will handle potato crisps and other snacks, significantly boosting logistics capacity and streamlining workflows without expanding the warehouse footprint.

The comprehensive solution includes six stacker cranes operating alongside racking equipped with Mecalux’s Automated Pallet Shuttle system. A floor-mounted electric monorail and automatic conveyors will ensure seamless, 24/7 pallet movement between the warehouse and production areas.

“With this logistics automation project, production, the warehouse and dispatch will be automatically connected,” says Bartłomiej Lesiuk, Warehouse Automation Design Manager at PepsiCo. “We’ve opted for a modular design that gives us the flexibility to adapt as our needs evolve.”

Mecalux’s Easy WMS warehouse management software will manage AS/RS operations, fully integrated with PepsiCo’s SAP eWM system for precise, real-time coordination from inbound goods to outbound shipments.

This marks Mecalux’s third warehouse project for PepsiCo Polska. The Grodzisk Mazowiecki facility incorporates innovative features such as energy recovery systems on stacker cranes, reducing energy use by 15-20%, and AI-powered computer vision technology replacing traditional photocells to enhance pallet positioning accuracy and safety.

“With this new investment, we expect to optimise operations, expand warehouse capacity and lower logistics costs,” says Lesiuk. “Automation will also allow us to make direct deliveries, avoiding double handling and unnecessary transport. On top of that, we estimate an annual reduction of 200 tonnes in greenhouse gas emissions.”

As a global leader in snacks and beverages with brands like Pepsi, Lay’s, and Doritos, PepsiCo continues to prioritize innovation and sustainability by adopting advanced technologies that optimize operations and reduce environmental impact.