Coca-Cola Bottlers Japan Akashi Mega Distribution Center

Project Overview

Coca-Cola Bottlers Japan undertook a major logistics transformation with its "Shinsei Project," aimed at optimizing operations to meet growing consumer demand. The Akashi Mega Distribution Center (DC) is a key component of this initiative, designed to serve the significant markets of Osaka and Hyogo Prefectures.

The facility was built to handle the immense scale and variety of shipping needs for beverage products. The primary goal was to create a highly automated, efficient distribution hub that could ensure a stable and reliable supply chain for the region, moving from traditional methods to an integrated, technology-driven operation.

Technical Solution

Unit Load Automated Storage/Retrieval System (AS/RS)

The system features a large-scale Unit Load AS/RS with a capacity of 60,000 pallets. This system provides high-density storage for full pallets of beverages, serving as the primary buffer between production or receival and the order fulfillment process.

Key Features

The combination of a 60,000-pallet AS/RS for bulk storage and a 72,000+ case Shuttle Rack for order assembly provides massive, automated storage capacity tailored for both full and mixed pallet workflows.

The robotic palletizing cells enable the automated creation of mixed-load pallets, which is essential for store-specific deliveries, while the RORO stations automate the final step, loading these pallets onto trucks with high throughput.

The DC is designed as a high-volume hub, integral to a supply network that ships 80 million cases annually, ensuring product availability across two major prefectures.

Results & Benefits

The facility is a cornerstone of a distribution network capable of handling 80 million cases of beverages each year, demonstrating its critical role in meeting large-scale demand.

A key outcome is the reliable and stable supply of products to the populous Osaka and Hyogo areas, achieved through the DC's high capacity and automated efficiency.

The automation, particularly the RORO loading stations, has enhanced efficiency across the entire logistics chain—from receiving raw materials or finished goods to compiling orders and loading outbound trucks—reducing cycle times and labor requirements.

Challenges & Solutions

The core business challenge was transforming logistics to efficiently meet the growing and diverse shipping requirements of a vast consumer base in a key region. The solution was the strategic "Shinsei Project," which included building the Akashi Mega DC and equipping it with a suite of advanced Daifuku automation technologies. This integrated system (AS/RS, shuttle, robots, RORO) created a streamlined, high-performance network capable of handling the complexity and volume.

System Integrator

Daifuku provided the advanced automation solutions and system integration for the Akashi Mega DC. They were responsible for the design, supply, and integration of the key systems, including the Unit Load AS/RS, the Shuttle Rack system, the Sorting Transfer Vehicles (STVs), the robotic palletizing/depalletizing cells, and the innovative RORO loading stations. Their technology helped Coca-Cola Bottlers Japan build the streamlined, high-performance distribution network required for the project.