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

Title:
Transforming end‑of‑line operations for a global food and beverage giant using MAG1000 conveyor solution

Client Overview:
This Fortune 500 food and beverage conglomerate, headquartered in Europe, operates over 400 factories in more than 150 countries and employs more than 300,000 people. To boost efficiency and maintain high quality at a key facility in India, the company sought to automate its end‑of‑line operations.

Key Stats:

• Full pallets handled per hour: 77
• Fleet of AMRs: 12
• Forklifts (and 21 operators) reallocated: 7
• Uptime: 99 % (24/7)

The Problem

High production volumes meant many forklifts were moving pallets in a confined space, creating safety hazards. Running three shifts 24 hours a day was costly and labor‑intensive. The client also wanted to reduce manual handling for hygiene reasons, but rigid conveyor systems lacked the flexibility needed for scaling.

Our Solution

Botsync deployed an integrated MAG1000 conveyor solution. Four production lines feed 12 robotic palletizers. As soon as a pallet is ready, a MAG1000 AMR automatically collects it and delivers it to outbound conveyors. Another MAG1000 drops off an empty pallet at the palletization station to keep operations flowing. A fleet of 12 MAG1000s manages a throughput of 77 finished‑goods pallets per hour.

Key Features

• Safe conveyor integration: The system adapts to existing conveyors and safely moves pallets through tight spaces.
• Fully automated through SyncOS: SyncOS connects palletizers, empty pallet dispensers and drop‑off conveyors, eliminating manual intervention.
• Agile and flexible: The no‑code platform allows on‑the‑fly changes to task priorities and drop‑off points—something fixed conveyor lines can’t do.
• Intelligent orchestration: SyncOS prioritizes tasks based on each robot’s capacity, maximizing efficiency in a congested environment.

Impact on Operations

• Reduced forklift dependency: Fewer forklifts lowered safety risks.
• Workforce optimization: Seven forklifts and 21 operators were reassigned to other roles without compromising throughput.
• Improved traceability: Each pallet’s ID is tracked from production to warehouse, enhancing inventory control.

Conclusion

By automating its end‑of‑line pallet transfer, this global food and beverage leader achieved safer, more flexible operations with higher throughput and fewer manual touchpoints. The MAG1000 system sets a new benchmark for end‑of‑line automation in the F&B sector and scales easily as demand grows.