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- Solutions by Technology
- Honeywell Intelligrated Variety Pack System
Automate & Optimize Variety Pack Production
Meet consumer demand for variety, reduce costs, and streamline operations
with intelligent automation designed for beverage manufacturers.
Variety packs have become a staple in the beverage aisle, driven by consumer demand for flexibility, discovery, and convenience. For manufacturers, this trend brings both opportunity and operational complexity. Manual variety pack assembly is labor-intensive, costly, and prone to errors. Honeywell Intelligrated’s Variety Pack System offers a turnkey automation solution that transforms variety pack production by reducing labor, improving inventory control, and meeting throughput goals.
Common Challenges We Solve
Labor Reliance & Volatility
Manual variety pack assembly can require up to 30 workers per shift, leading to high costs and unpredictable staffing. Automation can reduce labor needs to just 1–2 operators per shift.
Efficiency Losses
Manual unpacking and repacking adds hidden costs and slows production. Automated systems streamline the process, packing cans only once after filling.
Quality Control
Human handling increases error rates and product damage. Automated systems use barcodes and vision systems for precise SKU tracking and quality assurance.
Inventory Complexity
Real-time tracking and high-density storage simplify SKU management and reduce floor space requirements.
Safety & Floor Space
Automation minimizes repetitive motion injuries and optimizes facility footprint.
Outcomes We Drive
Higher Throughput & Scalability
Automated system achieves significant throughput rates—over 1,000 totes per hour (up to 88 cans per tote) with modular scalability.
Reduced Labor & Costs
Dramatic reduction in headcount and associated costs; variety packs can be produced at the same cost as single-flavor packs.
Improved Quality & Traceability
Automated handling reduces product damage and improves regulatory compliance.
Optimized Inventory & Floor Space
High-density automated storage and retrieval system (AS/RS) buffers flavors until all batches are ready, reducing WIP inventory and floor space needs.
Key Industries & Applications
Beverage Manufacturing
Alcoholic and non-alcoholic drinks, energy drinks, coffee samplers, and more.
Food & Beverage Packaging
Flexible for assorted flavors, sizes, and formats.
E-commerce & Retail
Supports high-variety, high-velocity product demands.
How the Variety Pack System Works
- The Variety Pack System is a turnkey solution including hardware, software, controls, engineering, shipping, installation, commissioning, and post-sales parts and support to maximize uptime. Rather than packing and breaking down single flavors, the system places single flavor cans into trays directly from the production line, stores them in a high-density automated storage and retrieval system (ASRS), and “buffers” them until all batches are produced.
Once all flavors are produced, the system retrieves trays of relevant flavors from storage and conveys to an outbound robot cell which places cans on a beverage conveyor to deliver to the variety packing process. The system uses robotic arms, a gantry system for storage and retrieval to racking, conveyor, and advanced software to store, retrieve, and assemble multi-SKU packs at high speed. - Automated Flow: Cans move from filling station to temporary storage. Once all flavors are ready, the system queues and presents the combination for variety pack assembly.
- System Components:
- Product Load Unload Station (PLUS) Modules: Transfer cans in/out of the system from filler lines to the packer.
- Recirculation Loop: Facilitates the transfer of full and empty trays in/out of the PLUS modules and AS/RS.
- AS/RS Modules: Store full and empty trays.
- Robotic Arms & Gantry System: Assemble multi-SKU packs at high speed.
- Integrated Controls: Barcodes and vision systems ensure precise SKU tracking and quality control.
- WCS: Software that coordinates between upstream processes (filling) and downstream processes (case packing & palletizing) to execute orders.
- Modular Design: The system comes with a base module but can be scaled to match operational needs by incorporating more modules for higher throughput requirements. The system is designed to manage both slim and standard can types; engineering consultation can also be considered to accommodate different product types.
Technical Specifications
| Feature | Base Unit | Additional Module |
| Throughput/Rate | 9 totes/min | +9 totes/min |
| FTE Reduction/Shift | Up to 14 | Up to 14 |
| Size/Footprint | 18m x 26.7m x 8.4m high | 9.2m x 26.7m x 8.4m high |
Fully customizable based on customer requirements.
Business Case & ROI
- Labor Savings: Reduce labor from 30 packers to 1–2 operators per shift.
- Efficiency Gains: Faster production, less WIP inventory, and improved consistency.
- Quality & Compliance: Automated handling ensures traceability and reduces errors.
- Floor Space Optimization: High-density storage minimizes footprint.
- Safety: Fewer workers exposed to repetitive tasks.
Frequently Asked Questions
Yes, the system accommodates both slim and standard cans, with potential for other formats via engineering consultation.
Base system achieves 9 totes/min; scalable with additional modules.
Yes, fully customizable to match operational needs and product types.
Turn Variety Pack Challenges into a Competitive Advantage
Ready to automate your variety pack production and capture new market opportunities?
Contact Honeywell Intelligrated for a demo or to discuss how the Variety Pack System can transform your operations.
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