The company will connect production and shipping with an automated system operating 24/7 to boost capacity and cut CO₂ emissions
In the third quarter of 2026, PepsiCo plans to open 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 chips and other snacks. It was designed to increase PepsiCo’s logistics capacity and optimize workflows without expanding the existing building.
The project involves implementing a comprehensive solution. It features six stacker cranes serving racking equipped with the Automated Pallet Shuttle. A floor-mounted electric monorail system and automatic conveyors will link the warehouse with the production lines, enabling a continuous, round-the-clock pallet inflow.
AS/RS operations will be overseen intelligently by Mecalux’s Easy WMS warehouse management system, which will be integrated with PepsiCo’s SAP eWM software. This two-way connection will precisely coordinate all logistics processes, from goods receipt to outbound shipments.
“With this logistics automation project, production, the warehouse, and shipping will be automatically connected,” says Bart³omiej 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 the third warehouse project Mecalux has delivered for 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 an energy recovery system, saving between 15% and 20% in energy consumption with every movement. They also incorporate an AI-powered computer vision system instead of traditional photocells, ensuring safe, accurate pallet positioning.
“With this new investment, we expect to optimize operations, expand warehouse capacity, and lower logistics costs,” says Lesiuk. “Automation will also allow us to make direct deliveries, avoiding double handling and unnecessary transportation. On top of that, we estimate an annual reduction of 220 tons in greenhouse gas emissions.”
