Quenching a Thirst to Maximize Warehouse Capacity at Pepsi Bottling Ventures
Customer Company Size
Large Corporate
Region
- America
Country
- United States
Product
- PAS PowerStore
Tech Stack
- Warehouse Management System (WMS)
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Productivity Improvements
- Customer Satisfaction
- Energy Saving
Technology Category
- Functional Applications - Warehouse Management Systems (WMS)
- Automation & Control - Automation & Process Control Systems
Applicable Industries
- Food & Beverage
Applicable Functions
- Warehouse & Inventory Management
Use Cases
- Warehouse Automation
- Inventory Management
Services
- System Integration
About The Customer
Pepsi Bottling Ventures (PBV) is the largest privately-held manufacturer, seller, and distributor of Pepsi-Cola beverages in the United States. Located in Garner, North Carolina, PBV operates a 54,000 square feet warehouse nestled in an old-growth pine forest south of Raleigh. The company is renowned for its extensive distribution network and a wide range of beverage products, including Pepsi, Diet Pepsi, Mountain Dew, Diet Mountain Dew, Aqua Fina bottled water, and various flavors and package assortments of Lipton Tea, Sunkist, and Diet Sunkist. PBV has been recognized for its quality and innovation leadership, having been named Bottler of the Year by Beverage Industry in 2013 and winning the PepsiCo North America Caleb Bradham Platinum Award twice. The company is committed to maximizing its operational efficiency and maintaining its leadership position in the beverage industry.
The Challenge
Before the installation of PAS PowerStore, Pepsi Bottling Ventures (PBV) faced significant challenges in their warehouse operations. The 54,000 square feet warehouse stored pallets on the floor, up to four high, which led to inefficiencies and operational issues. One of the major problems was the occurrence of pallet tumbles, which not only damaged products but also created sticky spillage, complicating the warehouse environment. Additionally, the manual tracking of pallet locations often resulted in the inability to find specific pallets, leading to product wastage when items were stored past their due date. This manual system also meant that storage space was not utilized efficiently, further exacerbating the operational challenges. The need for a more efficient system was evident as PBV sought to increase storage capacity and better manage their inventory without expanding the physical footprint of their warehouse.
The Solution
To address the challenges faced by Pepsi Bottling Ventures (PBV), the company decided to implement the PAS PowerStore, a revolutionary cart and lift-based warehouse automation technology. This system was chosen for its ability to significantly increase storage capacity by over 60% within the existing warehouse footprint. The PowerStore system consists of seven modules, accessible by eight vertical conveyors, 27 carrier sets, and 14 turntables, all designed to maximize productivity and ease of access for fork truck operators. The system's proprietary software integrates seamlessly with PBV's existing Warehouse Management System (WMS), allowing for precise tracking and management of inventory. Fork truck drivers can input and deduct pallets via a double-layer induction/deduction conveyor, with large screen monitors directing operators on cargo scheduling. This automation has enabled PBV to store and retrieve 7,800 pallets efficiently, without the need for additional square footage or labor. The implementation of PowerStore has transformed PBV's logistics operations, allowing for seamless distribution and improved inventory management.
Operational Impact
Quantitative Benefit
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