PepsiCo Poland continues to automate logistics processes, preparing to launch a new smart warehouse in Grodzisk Mazowiecki in the third quarter of 2026. The facility will be equipped with Mecalux technology and is intended to increase storage capacity and streamline material flows between production and dispatch without expanding the existing infrastructure. A key objective is to connect the production lines with the warehouse in a fully automated way, enabling continuous 24/7 pallet flow. The installation will include an automated Pallet Shuttle system working with six stacker cranes, as well as an electric monorail system (EMS) line and a conveyor system to provide internal transport between areas. Operations will be coordinated by Mecalux Easy WMS, bidirectionally integrated with PepsiCo’s SAP EWM system to enable control of processes from receipt of finished goods to dispatch.
Scope of investment and technologies
The new warehouse will be the third project delivered by Mecalux for PepsiCo Poland. The high-density Pallet Shuttle storage system combined with stacker cranes is intended to provide fast access to unit loads and support high turnover. The EMS monorail and conveyors will link receiving, storage and dispatch areas, maintaining continuous 24/7 material flow. The project aims to reduce manual handling and eliminate unnecessary rehandling by directly connecting production, the warehouse and shipping.
Operations management and efficiency
Easy WMS will manage pallet locations, transport orders and synchronization with SAP EWM. Two-way data exchange is intended to ensure inventory consistency and task sequencing from receiving to shipping. The stacker cranes will be equipped with an energy recovery system that saves 15–20% energy on each movement. In addition, a computer vision system supported by artificial intelligence will replace traditional photoelectric sensors and support precise pallet positioning.
– The new project will provide an automatic connection between production, the warehouse and shipping. We opted for a modular design that gives us high flexibility for future adaptations – says Bartłomiej Lesiuk, Warehouse Automation Project Manager at PepsiCo.
– With the new investment, we expect to optimize the warehouse process, increase storage capacity and reduce logistics costs. Automation will also enable us to make direct deliveries, avoiding double handling and unnecessary transport operations. We also anticipate a reduction of greenhouse gas emissions by 200 tonnes per year – adds Bartłomiej Lesiuk.
