Diageo is one of the world’s leading beverage manufacturers, with a globally recognised portfolio of premium spirits distributed across international markets. At its Belfast site, the company supports large-scale production, packaging and distribution within Diageo’s wider supply chain.

As demand increased, Diageo required a scalable, high-performance storage solution capable of improving pallet flow, increasing storage density and supporting reliable material movement within the existing facility footprint. The operation needed an automated system that could handle high pallet volumes, maintain traceability by batch ID and integrate with the site’s Warehouse Management System.

Diageo faced a series of operational and spatial challenges that made conventional warehouse expansion impractical.

Rapid Growth in Demand

Increasing global demand across Diageo’s product portfolio placed significant pressure on both storage capacity and operational throughput. Existing warehouse processes were struggling to keep pace with production volumes, creating inefficiencies and the risk of bottlenecks within the supply chain.

Complex Storage and Retrieval Requirements

The operation required precise pallet management within a controlled ambient environment. Every pallet needed to be stored according to its specific batch ID, ensuring full traceability and accurate sequencing for outbound distribution. This demanded a highly intelligent storage system capable of managing product flow with speed and precision.

Operational and Energy Efficiency Pressures

High pallet volumes and continuous material movement placed increasing strain on operational efficiency. Frequent warehouse traffic and inefficient handling processes were contributing to unnecessary energy consumption, increased operational costs, and reduced overall system performance.

To support continued growth, Diageo required a future-ready automation solution capable of increasing storage capacity, maintaining a consistent and reliable flow of materials, and optimising operational efficiency, all without expanding the facility footprint.

The implementation of the Moffett Automation AS/RS solution delivered significant operational improvements across Diageo’s Belfast facility, transforming warehouse performance while supporting long-term scalability.

Increased Storage Density

The high-density automated storage system enabled Diageo to maximise the use of its existing warehouse footprint, significantly increasing pallet storage capacity without the need for facility expansion.

High-Throughput Performance

With the combination of 10 Moffett Automation “Taxi” pallet shuttles and 3 VTUs, the system delivers fast, continuous pallet movement throughout the operation. The dual set-down inbound area and intelligent conveyor design ensure efficient handling of high pallet volumes with minimal disruption.

Improved Operational Efficiency

Automation has streamlined pallet handling and reduced dependency on manual processes, resulting in:

• Faster pallet movement and retrieval
• Reduced operational bottlenecks
• Improved material flow consistency
• Enhanced overall warehouse productivity

Continuous System Availability

The inclusion of a dedicated taxi maintenance zone allows servicing and inspections to be carried out without interrupting live operations, ensuring maximum uptime and long-term system reliability.

Optimised Pallet Flow

The integrated reject lane ensures that rejected pallets are automatically diverted away from the main inbound flow, preventing disruptions and maintaining continuous throughput across the system.

Full Warehouse Visibility and Control

Through seamless integration with Diageo’s Warehouse Management System (WMS), the solution provides:

• Real-time inventory tracking
• Accurate pallet traceability
• Intelligent storage allocation
• Optimised retrieval sequencing

This level of integration enables greater operational visibility, improved decision-making, and enhanced supply chain control.

Future-Ready Operations

The completed system provides Diageo with a scalable, future-ready intralogistics solution capable of supporting continued growth, increasing throughput demands, and evolving operational requirements for years to come.