Rochester Pharmaceuticals Inc. in the U.S. is working to demonstrate that AGV robots can efficiently handle sorting tasks in the right applications, offering valuable insights for full automation in retail and distribution sectors. The company's Rochester Drug Corporation (RDC) operates an 1,800-square-meter distribution center, where a mobile sorting robot named "Adam" is currently managing four channels with a capacity of 1,200 units. This robot plays a key role in sorting products accurately.
When a pharmacy order is sent to Adam’s workspace, operator Mike Collins scans the barcode and sends the order to the robot. Adam then navigates through the area, using its suction cup-equipped arm to place items into the correct sorting box. Once the task is complete, it returns to Collins. When asked about the reliability of the robot, Collins laughed and said, “My job is to oversee its execution—though it doesn’t make many mistakes.â€
Adam was introduced in January 2017 and completed its sorting test by March. Currently, the robot achieves a 95–98% accuracy rate, while voice-activated systems reach 99.9%. Ritzman explained, “If we can organize products on the shelves properly, the robot can avoid most errors.†He added, “If we integrate it into our automation system, RDC plans to expand to four robots. I’m confident it will work.â€
While automation is common in manufacturing, retailers like RDC have traditionally relied on manual labor for sorting due to its flexibility and lower cost. However, evolving market demands, especially from e-commerce, now require higher accuracy, faster order fulfillment, and more reliable staffing—especially during night shifts.
In the past, RDC had only conveyor belts and voice technology. But as business grew, finding reliable workers for late-night shifts became challenging. The center handled around 30,000 orders per night, requiring 45 workers, but slow-moving goods were particularly hard to sort.
“Working during these hours is tough,†said John Brunnan. “There’s a high turnover, and human error rates reached up to 40% annually.†To address this, RDC planned to build a highly automated facility in Fairfield, New Jersey.
The idea of using a robot came from a conversation between RDC’s former CEO Dodd and a pharmacist client, who joked, “Someone should invent a robot.†Coincidentally, the son of pharmacist Tom Garruzzo, a robotic expert at Carnegie Mellon University, was involved with IAM Robotics. Though not initially focused on logistics, he visited Rochester and studied the sorting process for slow-moving items.
Speed wasn't the main goal—sorting 100 items per hour met RDC’s needs. The robot was custom-designed for their environment, and after extensive testing, Ritzman was satisfied with its performance.
RDC took a gradual approach, calling it the “climb-walk-run-jump†method, to reduce risks. Initially, IAM staff handled technical issues and trained Collins. After training, he managed independently, though IAM still monitored performance via cloud data.
Looking ahead, RDC plans to double the robot’s sorting area, potentially doubling the number of orders it can handle. They also partnered with SSISchaefer to integrate the robot with conveyor systems, allowing sorting boxes to move automatically and freeing up Collins.
After six months of working with robots, Ritzman was surprised by how quickly IT systems integrated. “Transferring data between our systems and the robot was faster than expected,†he said. Robots are also learning to perform precise calculations, much like other automation tools.
Both Ritzman and Brunnmann believe robots are ready for companies willing to take the leap. Brennan said, “We knew automation would bring benefits when we opened our new center. It’s an experiment, but I believe it will pay off.â€
Ritzman sees a future where robots redefine distribution centers. “We’re expanding to 10 states. With mobile robots, we can grow without needing more staff.†Automation, once a distant dream, is now a reality—and it’s just getting started.
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