Automation in Motion: AMR Robots supporting smarter logistics at Constantia ColorCap

Over the past few months, Constantia ColorCap has introduced and tested a new autonomous mobile robot (AMR) system in its warehouse and production environment. The project marks an important step toward smarter internal logistics, supporting efficiency, safety, and reliable material flow across the site.

The system is designed for the automated internal transport of half‑pallets within the production plant and operates continuously in an industrial 24/7 environment. Its main purpose is to move finished products and empty half‑pallets between production lines, buffer areas, and the warehouse, significantly reducing manual handling and forklift usage. A half‑pallet is a smaller version of a standard pallet used to transport loads internally, making it easier and more efficient to move smaller quantities of products within a production facility.

How the AMR system works

The solution is based on KUKA autonomous mobile robots (AMR), model KMP 600P, managed by KUKA.AMR Fleet software and fully integrated with the company’s ERP system.

Key functions include:

• automatic pick‑up of full half‑pallets from production stations
• transport to the main warehouse, shipping preparation areas, or defined buffer locations
• return of empty half‑pallets back to production areas
• fully autonomous task execution without human intervention
• navigation via SLAM laser technology and precision markers
• obstacle and people detection using 360° safety laser scanners and 3D cameras
• automatic driving to charging stations when battery levels are low

The robots communicate with the ERP system (transport orders), Siemens S7‑1200 PLC (automatic gate control), and a central monitoring PC for supervision and task prioritization. Each robot can safely transport loads of up to 160 kg per half‑pallet, operating entirely inside the production facility.

Benefits for daily operations

The introduction of AMR technology brings clear benefits across several dimensions:

Increased efficiency

• continuous and predictable material flow
• reduced waiting times for empty pallets at production lines to around 5 minutes
• optimized logistics between production and warehouse

Reduced manual work

• elimination of repetitive and heavy pallet handling
• reduced dependence on forklifts
• operators can focus on value‑adding tasks

Improved safety

• advanced safety features including laser scanners, 3D obstacle detection, emergency stops, and dynamic safety zones
• compliance with the EU Machinery Directive (2006/42/EC) and relevant ISO standards
• significantly lower risk of accidents related to manual transport

Transparency and control

• real‑time tracking of pallet locations
• centralized monitoring via PC interface
• ERP integration for better planning and prioritization

Scalability and future readiness

• easy expansion with additional robots, buffer locations, or transport scenarios
• adaptable to future production growth and layout changes​​​​​​​​​​​​​​

Following successful testing, the system has been approved for operation and is now ready to support daily production and logistics processes at Constantia ColorCap.

This project is a strong example of how targeted automation helps improve safety, efficiency,  and reliability — while supporting our teams in their everyday work.