Coca-Cola Andina: Automation and Sustainability at the Duque de Caxias Plant
Automation, flexibility, and safety were the guiding principles behind the project for Coca-Cola Andina's new plant in Duque de Caxias, Brazil.
Certified LEED Gold by the U.S. Green Building Council, the plant was designed to ensure the highest possible quality in both products and operations, to prioritize employee safety and well-being, and to promote environmental protection and sustainability. "The plant was designed with sustainability in mind. In this context, the technologies provided by the E80 Group played a strategic role in combining operational efficiency, safety, and resource conservation," explains Fausto Padrão, Engineering Manager at Coca-Cola Andina Brasil. In addition to automation and the application of digital solutions, targeted choices—such as responsible water resource use, the inclusion of natural lighting and ventilation, and the preservation of a large ecological park within the plant's grounds—have made this initiative a recognized benchmark within the Coca-Cola system.
A Decentralized and Digitalized Production Model
The Duque de Caxias plant was built around clear principles: high productivity with high-volume, high-speed lines; flexibility to produce a variety of products across multiple categories; scalability through a simple, modular design that supports long-term growth; and, importantly, extensive digital integration using cutting-edge technologies. To achieve these goals, Coca-Cola Andina adopted a decentralized layout in which each production line functions as an autonomous “mini-factory,” equipped with its own systems for cooling, production, and CIP (Clean-In-Place). "Our engineers," says Fausto Padrão, "understood that decentralizing operations would be a bold but effective move. This decision allowed each line to operate independently, simplifying planning and increasing efficiency, autonomy, and speed. The entire facility was designed to accommodate LGVs." This modular configuration reduced setup times, improved productivity, and facilitated operational control. "Each line operates with greater agility while maintaining high-quality standards."
Technological Choice: Flexibility and Integration
Among the intralogistics solutions evaluated, Coca-Cola Andina immediately ruled out any that did not align with the vision of a highly flexible, safe, and digital plant. "We assessed the leading market solutions based on the criteria that guided the project," explains Fausto Padrão. "In fact, the only way to achieve these goals was through automation with laser-guided vehicles—not only for managing raw materials and feeding the production lines, but also for picking finished products and handling waste. Thanks to the E80 Group's laser-guided vehicles, "we were able to meet all our expectations: they’re not only precise and flexible, but also easy to integrate with our systems, including digital platforms."
Operational Safety and Production Continuity
The use of LGVs had a major impact on safety, both for personnel and infrastructure. "The LGVs are equipped with numerous sensors that ensure safe operation in all types of environments—among materials, structures, and even when workers are nearby. Without a doubt, they are extremely reliable," Padrão emphasizes.
The benefits are significant: better protection of infrastructure, more accurate warehouse management, fewer errors and accidents, and significantly enhanced real-time traceability and monitoring of handled products, ensuring their integrity. Thanks to these vehicles, storage quality has also improved, and most importantly, employee safety has increased. Perhaps the most important benefit for our company is exactly that—ensuring the safety of our team. "For our operators, performing their daily tasks with the help of LGVs means working under the safest possible conditions. They’ve become part of our daily routine,” he adds.
Automation was accompanied by intensive training and constant supervision. Ongoing support and regular reporting from the E80 Group ensure reliability and continuity of production.
"Despite the high level of automation and reliability,” concludes Fausto Padrão, "no system is immune to potential interruptions. In the beverage industry, even the smallest disruption in operations can have a big impact.
Thanks to our company’s continuous commitment and the E80 Group’s support in training our operators, we receive daily activity reports and have 24/7 assistance—ensuring the plant’s uninterrupted operations."