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PepsiCo automates logistics processes in Poland with a new Mecalux AS/RS
06.10.2025
In the third quarter of 2026, PepsiCo plans to deploy a new automated storage and retrieval system (AS/RS) in Grodzisk Mazowiecki (Poland) with Mecalux technology. Connected to the production area, the solution will accommodate potato crisps and other snacks. It was designed to increase PepsiCo’s logistics capacity and optimise workflows without expanding the existing building.
The project involves implementing a comprehensive solution. It features six stacker cranes serving racking equipped with theAutomated Pallet Shuttle. A floor-mountedelectric monorail systemand automaticconveyorswill link the warehouse with the production lines, enabling a continuous, round-the-clock pallet inflow.
AS/RS operations will be overseen intelligently byMecalux’s EasyWMS warehouse management system, which will be integrated withPepsiCo’s SAP eWMsoftware. This two-way connectionwill precisely coordinate all logistics processes, from goods receipt to outbound shipments.
»With this logistics automation project,production, the warehouse and dispatch will be automatically connected,« saysBartłomiej 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.«
This new AS/RS will be thethird warehouse project Mecalux has deliveredfor PepsiCo Polska. In addition to its link with production and 24-hour operation, the Grodzisk Mazowiecki facility features several key tech innovations. The stacker cranes are equipped with anenergy recovery system, saving between 15% and 20% in energy consumptionwith every movement. They also incorporate anAI-poweredcomputer visionsystem instead of traditional photocells, ensuring safe, accurate pallet positioning.
»With this new investment, we expect to optimise operations,expand warehouse capacity and lowerlogistics costs,« says Lesiuk. »Automation will also allow us to make direct deliveries, avoiding double handling and unnecessary transport. On top of that, we estimate anannual reduction of 200 tonnes in greenhouse gas emissions.«