Kraft Heinz Automated Layer Picking Implementation Case Study
Case study of Kraft Heinz UK DC implementing Körber Layer Picker Flex-R to increase automated layer picking without product changes.
This case study details the 2015 deployment of a Körber Layer Picker Flex-R system at Wincanton's National Distribution Centre in Wigan, managed for Kraft Heinz. The solution addressed the need to raise automated layer picking rates for mixed-product pallets while maintaining existing product configurations. Testing of over 60 SKUs validated throughput of 180 layers per hour, enabling the DC to target 90% of outbound volume untouched by hand.
Layer Picker Flex-R increased automated layer picking volume significantly toward 90% hand-free dispatch target
System handles 60+ previously unpickable product configurations with sandwich/rainbow pallet creation
Achieved 180 layers per hour throughput with 24/7 operational capability
Integration with existing conveyors upgraded older installation without full system replacement
Enabled later dispatch cutoffs and improved vehicle loading flexibility
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