High-Throughput Automated Storage for YAYA Foods
A high-capacity food and beverage warehouse automation project powered by 44 Moffett Automation Taxi pallet shuttles, 7 VTUs and an advanced conveyor network.
Key Figures at a glance:
| Location | Canada |
| Operational Time | 12 hours per day, 6 days per week (inbound 12 hours per day) |
| Throughput IN | 100 pallets per hour |
| Throughput OUT | 300 pallets out per hour, constant |
| Pallet Shuttles | 44 Moffett Automation Taxi pallet shuttles |
| Building Height | 42.6 feet |
| VTUs | 7 Moffett Automation VTUs |
| Inbound Locations | 6 |
| Outbound Locations | 4 |
| Special features | Complex conveyor system and 44 Moffett Automation Taxi pallet shuttles to support high-throughput pallet flow |
Moffett Automation delivered a high-throughput automated storage and intralogistics system for YAYA Foods, designed to support rapid product output, balanced pallet flow, safer handling and scalable food and beverage warehouse operations.
Project Overview
YAYA Foods Corp. is a Toronto-based beverage and liquid food co-packer operating in a high-volume production environment. As output increased, the business required an automated storage and handling system capable of supporting rapid product movement, ambient storage and significant outbound pallet demand.
Moffett Automation designed and delivered a high-throughput automated storage solution combining 44 Moffett Automation Taxi pallet shuttles, 7 Moffett Automation VTUs, advanced conveyor integration and warehouse control software. The system was built to balance pallet flow, support high outbound volumes and give YAYA Foods a scalable platform for future growth. Project objectives:
- Support high-throughput inbound and outbound pallet movement
- Balance pallet flow across storage, conveyors and operational areas
- Integrate 44 Moffett Automation Taxi pallet shuttles with an advanced conveyor network
- Deliver a software-driven system designed for efficiency, reliability and scalability
Challenges Presented
Managing High-Volume Pallet Flow Across Complex Infrastructure
YAYA Foods needed to manage a significant imbalance in pallet flow, with substantially more pallets leaving the system than entering. The facility required an automated solution capable of maintaining throughput, reducing bottlenecks and keeping pace with high-volume beverage and liquid food production.
The project also required close coordination between conveyors, Moffett Automation Taxi pallet shuttles, warehouse personnel and warehouse control software. The system needed to support ambient food storage, improve operational visibility and provide scalable capacity for future production growth.
Storage Transformed
A High-Throughput Automated Storage and Intralogistics System
Moffett Automation delivered a high-throughput automated storage and intralogistics system designed around YAYA Foods’ production output, pallet flow and ambient storage requirements. The system combines shuttle-based pallet movement, vertical transfer, conveyor integration, warehouse control software and safety infrastructure to create a scalable automated operation.
Moffett Automation Taxi pallet shuttles
44 Moffett Automation Taxi pallet shuttles were deployed to move pallets efficiently between storage, conveyors and operational areas.
Moffett Automation Conveyor
The conveyor network was integrated with the wider warehouse infrastructure to support smooth inbound and outbound pallet movement.
Moffett Automation VTU
7 Moffett Automation VTUs were introduced to support vertical pallet movement and improve use of available warehouse height.
Moffett Automation WCS
Moffett Automation implemented warehouse control software to manage pallet storage, traffic control, route scheduling and system coordination. The software was integrated with YAYA Foods’ existing WMS to support real-time visibility and operational control.
Safety measures
The project included fencing, light curtains and other safety measures to support safe interaction between automated equipment, conveyors and warehouse personnel.
Technical online support
Moffett Automation provides 24/7 remote technical support from its in-house team to help maintain system availability and respond quickly to operational issues.
Local mechanical support
The Moffett Automation system is supported by a local service partner providing preventative maintenance and rapid 24-hour on-site response when required.
Project Results
Higher throughput, balanced pallet flow, and streamlined handling have strengthened YAYA Foods’ operational efficiency.
The Moffett Automation system strengthened YAYA Foods’ operational efficiency by increasing throughput, balancing pallet flow and streamlining pallet handling across the facility.
The solution delivered 35,913 pallet locations for ambient food storage and supported high-volume pallet movement, with 100 pallets per hour inbound and 300 pallets per hour outbound. The automated transfer operation, powered by 44 Moffett Automation Taxi pallet shuttles and a sophisticated conveyor network, improved material flow, reduced handling complexity and supported faster outbound processing.
Warehouse control software gave YAYA Foods real-time visibility over pallet movement, route scheduling and throughput. This improved operational coordination and created a more scalable system for future demand. By reducing excessive forklift traffic and automating pallet transfers, the system also helped reduce congestion and improve safety for warehouse personnel.
Interested in Automating Your Warehouse in North America?
Speak to Moffett Automation’s North American sales team about high-throughput automated storage, pallet shuttle systems, WMS integration and scalable warehouse automation for food and beverage operations.
Gary Chapman
Email: [email protected]
Phone: +1 416 574 5273
Gary Chapman
