Revolutionizing Pallet Transfer for a Global Beverage Leader using integrated AMR and software solutions

Title:
Revolutionizing pallet transfer for a global beverage leader using integrated AMR and software solutions

Client Overview:
Our client is a globally recognized soft‑drink brand with a broad product portfolio and a long history of memorable marketing campaigns. Their products are sold in more than 200 countries, making them one of the world’s top beverage companies.

Key Stats:

• Pallets handled per hour: 44
• Fleet of AMRs: 5
• Uptime at 99 %, 24/7 operations
• Forklifts and operators reallocated: 3 forklifts, 9 operators

The Problem

The factory struggled to move heavy finished‑goods pallets through a narrow, congested environment. Forklifts were the only option, but they posed safety risks and required numerous trained operators across three shifts to keep production running. Management needed to maintain throughput and product quality while reducing reliance on forklifts and labour.

Our Solution

Botsync engineered an integrated MAG1000 conveyor solution in partnership with the client. Finished‑goods pallets from two separate production areas—some requiring strapping before storage—are now moved autonomously. SyncOS connects conveyor systems, strapping cells and MAG1000 AMRs to ensure pallets travel smoothly from production to the warehouse.

Key Features

• Fully integrated automation: SyncOS Integrator links conveyor and strapping PLCs (via Kepware), the fleet manager, SCADA and warehouse‑management systems, creating a cohesive workflow.
• High configurability: The system dynamically adjusts AMR speed based on the type of pallet—strapped or unstrapped—so safety and throughput are both maintained.
• Intelligent fleet orchestration: Operating multiple AMRs in a tight space required sophisticated task prioritization. SyncOS ensures each robot takes on the right job at the right time, maximizing capacity.

Impact on Operations

• Fewer forklifts, improved safety: Automation dramatically reduced forklift use, minimizing risks in tight aisles.
• Reallocated staff: Three forklift drivers and nine operators were freed up for other roles while production throughput stayed high.
• Better product quality: By limiting human contact with finished goods, the system reduced handling and potential damage.

Conclusion

Botsync’s integrated AMR and software solution transformed pallet transfer for this beverage manufacturer. It maintained high throughput, cut labour needs, and boosted safety in a constrained environment. The success underscores how targeted automation can streamline complex workflows and support scalable growth.