Case Studies

Implementation of AMRs in a Soft Drink Manufacturing Facility

We identify process gaps and deploy intelligent automation solutions that improve efficiency, reduce downtime & scale your operations.

Aug, 2019
Implementation of AMRs in a Soft Drink Manufacturing Facility

Introduction

A leading soft drink manufacturing company faced operational inefficiencies and product handling risks in its internal material transfer process. The existing system relied on human-operated forklifts for transporting finished bottle batches, leading to inefficiencies and product handling risks.To address these challenges, a fleet of multiple Autonomous Mobile Robots (AMRs) was deployed to automate and optimize the workflow.

Problem statement

Existing Workflow:

  • Bottled soft drinks were grouped and wrapped into bulk units (~500 kg per load).

Key Issues:

  • Product Instability & Damage Risk
    • Wrapped bottle stacks were prone to imbalance during forklift transport, increasing chances of falling loads.
  • Limited Throughput
    • Manual operation created inconsistent transfer cycles.
    • Bottlenecks between production and packaging lines.
  • High Maintenance Overhead
    • Increased servicing and downtime costs.
Takeaways

Key Takeaways from This Case Study:

A key performance breakthrough was the increase in load handling capacity—from 0.5 tons per transfer using forklifts to 2.5 tons with the AMR system. This substantial improvement not only reduced the number of trips required but also led to a noticeable enhancement in overall cycle time and throughput efficiency.

The company achieved higher efficiency, reduced operational costs, and significantly improved safety and product handling reliability.

What makes this project strong isn’t just “AMRs were deployed”—it’s that:

  • Every design choice was context-driven.
  • We reduced infrastructure dependency
  • And built a system that is scalable, adaptive, and production-ready
TakeawaysTakeaways
Our RoleOur RoleOur Role

Vrutti’s Role

Implementation Strategy:

  • AMR Integration (OEM Collaboration)
    • Close collaboration with OEM AMR manufacturers for system deployment.
    • Provided inputs to improve load handling stability
    • Integration of software stack with OEM hardware platforms.
  • Limited Throughput
    • Configuration of:
      • Dynamic obstacle detection
      • Safe operating zones
  • High Maintenance Overhead
    • Real-world load testing up to 2.5 tons
    • Iterative tuning for navigation and docking accuracy

Factory Simulation for Flawless AGV Deployment:

A barrier-based control mechanism was integrated into the workflow

How it works:

  • As the AMR approaches → barriers automatically close
  • During loading/unloading → restricted access for safety
  • After task completion → barriers reopen

Impact:

  • Prevents human interference during critical operations
  • Ensures safe and controlled material transfer zones

"This project was executed through a collaborative ecosystem where we acted as the automation and software intelligence layer—bridging OEM AMR capabilities with real-world factory requirements."

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