Project C – Automated Wholesale Distribution Center

Project C centers on a major wholesale distributor serving thousands of convenience stores across the United States through both B2B and B2C channels. To improve fulfillment speed, accuracy, and long-term scalability, the customer invested in a fully automated 130,000 sq.ft. distribution center in Huntsville, Alabama. This facility became the cornerstone of their modernization strategy, supporting nationwide service levels and high-volume replenishment.

The distribution center operates a complete end-to-end AMR-driven workflow that spans receiving, putaway, rack-to-person picking, pallet-to-person handling, stamping and labeling, order consolidation, wrapping, and outbound shipping. The automation ecosystem includes 80 P800 robots responsible for pallet and rack handling and 12 RS robots supporting high-density tote-based storage and picking. Together, they form a high-throughput, multi-zone robotic system designed to reduce manual handling and support continuous operations.

After the system was deployed, the customer partnered with PB RoboTech to provide long-term onsite automation support through a dedicated Resident Technician Program. Under this model, PB maintained a full-time presence at the facility, delivering preventive maintenance, corrective repairs, on-floor troubleshooting, and rapid response to any operational disruptions. The resident team continuously monitored robot performance, supported software updates and hardware replacements, and collaborated closely with the client’s PM and operations teams to address issues proactively and transparently.

PB’s onsite support played an essential role in stabilizing daily operations across all automated zones. With resident technicians handling technical risks and maintenance demands, the site maintained consistently high uptime and minimized disruption to fulfillment activities. The AMR-driven workflows delivered strong picking efficiency, accuracy, and reliability, while the quick response capabilities of PB’s team ensured that operational challenges were resolved before they escalated. As a result, Project C benefited from reduced manual labor intensity, increased processing capacity, and a dependable automation foundation that could scale with future business growth.

Project C demonstrates the combined value of advanced warehouse automation and sustained professional system support. Technology alone does not guarantee performance—ongoing technical care, real-time monitoring, and a disciplined maintenance program are equally critical to realizing long-term ROI. PB RoboTech’s Resident Technician Program provided exactly that, enabling the customer to operate confidently under high order volumes while reducing operational risk.

Through continuous onsite involvement, proactive maintenance practices, and rapid technical intervention, PB RoboTech helped the customer maintain a smooth, efficient, and high-performing automated distribution center—strengthening service levels across their nationwide convenience-store network and maximizing the value of their automation investment.