Warehouse
77 Full Pallets Per Hour
7 reduction of forklifts and 21 forklift operators
12 Fleet of AMRs
24/7 Operations with 99% uptime

Transforming End-of-Line Operations for a Global Food & Beverage Giant using MAG1000 Conveyor Solution

Our client is a Fortune 500 food and beverage conglomerate, headquartered in Europe. The company has a global footprint of over 400 factories in more than 150 countries, and employs over 300,000 people. As part of their automation roadmap, they sought to automate their end of line operations at a key factory in India. They needed a reliable automation partner to ensure safety, flexibility, and efficiency in automating their end-of-line processes.

77 Full Pallets Per Hour
7 reduction of forklifts and 21 forklift operators
12 Fleet of AMRs
24/7 Operations with 99% uptime

The Problem

Due to high production volumes, the factory required numerous forklifts in a confined space, creating significant safety risks. Maintaining business continuity was also a challenge, as it required staffing for three shifts 24/7, which led to high costs and labor availability concerns. In addition, the client wanted to reduce human touchpoints to maintain quality and hygiene standards. Traditional conveyor systems were too rigid and limited the client’s ability to scale or remain agile.

Our Solution

Integrated MAG1000 Conveyor Solution

Botsync worked with our partners to deploy an integrated AMR solution that could automate the transfer of Finished Goods (FG) pallets to the warehouse, safely and reliably.

Packaged food products coming out of 4 production lines are palletized by 12 separate robotic arms. As soon as a pallet is ready, the MAG1000 system is automatically assigned to pick it up and transfer it to the outbound conveyors. In parallel, another MAG1000 transfers empty pallets to the palletization station to ensure there is zero downtime. With this system, a fleet of 12 MAG1000s managed an overall throughput of 77 FG pallets per hour.

Key Features
Accurate and safe conveyor transfer

Accurate and safe conveyor transfer

The solution was specifically designed to adapt to existing conveyors and operate in the confined space, and was able to safely and consistently ensure the transfer of the pallet from the palletisation station to the drop-off conveyors using the fleet of AMRs.

Highly integrated & fully automated

Highly integrated & fully automated

The SyncOS™ integrator connected the palletization station, empty pallet dispensers, and drop-off conveyors, enabling the entire process to run without human intervention.

Agile and flexible design

Agile and flexible design

The agile nature of MAG1000 and the no-code SyncOS™ platform allowed the client to change task prioritization, drop-off locations, and rules on the go, providing the flexibility that would not have been possible with a traditional conveyor system.

Intelligent orchestration

Intelligent orchestration

Operating in a congested environment with multiple AMRs, the solution required advanced fleet management with intelligent task prioritization. Thanks to SyncOS™, we were able to prioritize tasks based on each machine’s capacity and restrictions, to ensure optimal utilization of their capacity.

Impact On Operations

  • Reduced need for extensive forklifts deployments, which lowered safety risks.
  • Reduction of 7 forklift drivers and 21 forklift operators, which led to a maintenance of production throughput with minimum human resources.
  • Improved trackability of inventory by ensuring all pallet IDs are tracked throughout the transfer process to the warehouse.

Conclusion
The deployment of the MAG1000 AMR system at the client’s facility transformed their operations, providing the agility, safety, and scalability needed to meet increasing production demands. The system not only optimized labor resources but also enhanced product handling quality, setting a new benchmark for end-of-line automation in the food and beverage industry.

Case Studies