Coca-Cola Amatil — Auckland Distribution Centre
Coca-Cola Amatil's Auckland distribution centre deployed a fully automated palletization system using KUKA robot cells integrated with Swisslog's high-bay pallet storage and CycloneCarrier shuttle system. The project replaced manual voice-activated picking with a system capable of handling 1,000 cases per hour.
Three KUKA robot cells handle up to four packages at a time, building mixed pallets configured to individual store requirements — enabling efficient shelf restocking at retail outlets.
"We are so impressed with this technology and the level of efficiency afforded by the fully automated cardboard box picking system."
— John Truscott, General Manager Supply Chain, Coca-Cola Amatil New Zealand
Mondelēz International — $130M National Distribution Centre
Swisslog installed 11 Vectura stacker cranes (32m tall), 22 dual-load inverted monorail trolleys, 490m of pallet conveyor, 16 dual pallet flow lanes, and SynQ WES software for Mondelēz's first national DC in Australia — handling Cadbury, Pascall, The Natural Confectionery Company, OB Finest and Olina's.
The ASRS serves 56,100 of 85,000 total pallet locations, with room to expand to 62,000 as the business grows. Designed throughput: 218 inbound pallets/hour and 255 outbound pallets/hour. The facility uses 100% renewable electricity and generates approximately 1MW of solar power.
"Swisslog was able to present the best solution for the long-term benefit of our operations. The automation solution also increases the safety of our operational personnel, removes our error handling, upskills our team in automation and improves our truck turnaround times."
— Wayne Angus, Supply Chain Vice President ANZ, Mondelēz International
Sunoko Sugar — 10 Tonnes Per Hour Palletizing
Sunoko, Serbia's largest sugar producer with 50%+ market share, automated its 10/1 kg sugar packaging line at the Kovačica plant. System integrator multi-tec deployed two KUKA KR 120 R3200 PA robots to palletize packages ranging from 750g to 50kg — a throughput impossible with manual labour.
The robots lift packages from a roller conveyor, stack them on Euro pallets, apply protective foil between layers and wrap completed pallets automatically.
Ramah Water Factory — 81,000 Bottles Per Hour
KUKA system partner MEMCO deployed a three-robot palletizing line at the Ramah Water Factory — two KR 40 PA robots for precise bottle positioning and a KR 700 PA for full-layer palletizing. The system processes 81,000 bottles per hour across multiple bottle types simultaneously.
KUKA.ConveyorTech software synchronises robot movements with conveyor speed, while KUKA.PLC mxAutomation enables layer configuration changes with a single touch.
"Automation was the logical approach for us because they can meet our high requirements while they work with maximum cost-effectiveness."
— Ibrahim Alassaad, MEMCO Project & Design Director
Pepsi / Jordan ICE — Beverage Warehouse Palletizing
Jordan ICE, the Pepsi bottling operation in Jordan, replaced numerous manual workers with a single KUKA KR 700 PA robot for fully automated palletizing. The robot handles over 2,100 cans per pick cycle, building custom pallets configured to individual store requirements.
System integrator Technica International SAL delivered the solution — the first KUKA project for this integrator, which now plans to expand the solution to other plants worldwide.
"Automation was the only way to make the process as effective as possible. And KUKA had the most suitable robot for us."
— Bechara Nassar, Technica International SAL
TPV Displays Polska — 22 AMRs Automate Internal Transport
TPV Displays Polska, a leading European TV manufacturer, deployed 22 KUKA KMP 1500P AMRs at its Gorzów Wielkopolski plant. The robots fully automate material transport between the warehouse and 10 assembly lines, replacing manual electric cart operations.
The AMR fleet operates 24/7 with inductive charging, managed by KUKA's AMR.Fleet software. The system also works alongside 40+ KUKA industrial robots on the production floor.
"The combination of stationary robots and AMRs improves the efficiency of supply to assembly lines, increases flexibility, and integrates material flow and storage into a high-performance system."
— Grzegorz Benda, Technical Director, TPV Displays Polska
Albertsons Dairy — Cold Storage Palletizing
Food company Albertsons worked with KUKA system partner IPM (Integrated Packaging Machinery) to automate its dairy line. A KUKA robot now stacks milk crates on pallets inside a cold storage warehouse — eliminating back-breaking manual labour in icy conditions.
The solution is rated for cold storage environments, handling the heavy, repetitive lifting that was previously performed by workers in refrigerated conditions throughout their shifts.
"It's very cold in the refrigerator, and the work is back-breaking and the cases are just too heavy for someone to be in there palletizing all day long."
— Kendal Malstrom, VP Operations, IPM
Dean Foods — First Stainless Steel Robot in North America
KUKA installed the first stainless steel robot in North America at Dean Foods' dairy manufacturing facility. The KUKA KR 15 SL handles dairy case packing in a sterile environment — meeting strict food safety standards while increasing production throughput.
The stainless steel robot can be cleaned daily with acids and alkalis without damage, and requires no protective suit — freeing four employees from wash-down requirements.
Danfoss — Vision-Guided Machine Tending for 100+ Component Types
Danish manufacturer Danfoss deployed six KUKA robots with 3D vision systems to automate machine loading and unloading across its production facility. The system recognises over 100 different component types using Roboception's rc_visard 3D sensor and SilhouetteMatch software.
KUKA KR QUANTEC robots load grinding machines while KUKA KR CYBERTECH robots handle washing, sorting and secondary operations — all without manual intervention.