In the third quarter of 2026, PepsiCo Polska plans to launch a smart warehouse in Grodzisk, Poland, and it needed automation that could accommodate potato chips and other snacks. It also wanted to increase its logistics capacity and optimize workflows without expanding the existing building. The company decided to automate storage with technology from Mecalux International.
“With this logistics automation project, production, the warehouse, and shipping will be automatically connected,” said Bartomiej 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.”
Harrison, N.Y.-based PepsiCo Inc. is one of the world’s largest snack food and beverage companies. The multinational said it is driving innovation in both production and logistics processes, as it adopts advanced technologies across its production plants and warehouses.
PepsiCo added that it has demonstrated a growing commitment to sustainability, investing in practices that minimize the environmental impact of its operations and foster a responsible supply chain.
PepsiCo to deploy ASRS in Poland
PepsiCo’s Polish division plans to implement an automated storage and retrieval system (ASRS). The project features six stacker cranes serving racking equipped with Mecalux’s Automated Pallet Shuttle.
A floor-mounted electric monorail system and automatic conveyors will link the warehouse with the production lines, enabling a continuous, round-the-clock pallet inflow.
Mecalux said its Easy WMS warehouse management system will intelligently oversee ASRS operations. It will be integrated with PepsiCo’s SAP eWM software. This two-way connection will precisely coordinate all logistics processes, from goods receipt to outbound shipments, the company explained.
In addition to its link with production and 24-hour operation, the Grodzisk Mazowiecki facility features several innovations, noted Mecalux. The stacker cranes are equipped with an energy recovery system, saving between 15% and 20% in energy consumption with every movement.
It said they also incorporate an AI-powered computer vision system instead of traditional photocells, ensuring safe, accurate pallet positioning.
Mecalux continues optimizing operations
The new ASRS will be the third warehouse project Mecalux has delivered for PepsiCo. It previously installed robots in PepsiCo’s Środa Śląska factory, as well as in a Belgian plant.
“With this new investment, we expect to optimize operations, expand warehouse capacity, and lower logistics costs,” said Lesiuk. “Automation will also allow us to make direct deliveries, avoiding double handling and unnecessary transportation. On top of that, we estimate an annual reduction of 220 tons in greenhouse gas emissions.”
With over 55 years of experience, Mecalux develops automated storage systems, intralogistics and warehouse management software, and metal racking systems for all sectors. The Barcelona, Spain-based group has an extensive worldwide distribution network, 12 manufacturing plants, seven research and development centers, and more than 5,500 employees.
Also in food and beverage, Mecalux recently deployed its semi-automated pallet shuttle system at Coca-Cola HBC Ireland and Northern Ireland.
