Rochester Pharmaceuticals Inc. in the United States is exploring how AGV robots can effectively handle sorting tasks in specific applications, aiming to provide real-world insights for the full automation of retailers and dealers. The company, Rochester Drug Corporation (RDC), operates an 1,800-square-meter distribution center where a mobile sorting robot named "Adam" plays a key role.
Currently, Adam manages four channels with a capacity of 1,200 units. It sorts products efficiently by identifying and placing items into the correct sorting boxes. When a pharmacy order arrives, operator Mike Collins scans the barcode and sends the task to Adam. The robot then moves through the workspace, using a suction cup-equipped arm to sort the goods accurately. Once the order is complete, it returns to Collins, who supervises the process. “My job is just to make sure it does what it’s supposed to,†he says with a smile. “It doesn’t make many mistakes.â€
Adam was introduced in January 2017 and completed its initial sorting tests by March. Its current accuracy rate ranges between 95% and 98%, slightly lower than voice-activated systems at 99.9%. According to Ritzman, improving shelf organization could significantly reduce errors. He also mentioned that RDC plans to expand from one to four robots, confident that automation will work well.
While automation is common in manufacturing, many retailers and distributors have been slow to adopt it due to the flexibility and cost-effectiveness of human labor. However, evolving market demands—especially in e-commerce—require higher accuracy, faster order fulfillment, and more reliable shifts. Traditional models are no longer sufficient, making automation essential for efficient sorting and packaging.
RDC initially relied on basic automation like conveyors and voice technology. But as business grew, labor shortages became a problem, especially during night shifts. Sorting slow-moving items was particularly challenging, leading to high error rates. To address this, RDC planned to build a highly automated facility in Fairfield, New Jersey.
The idea of using a robot came from a casual conversation between RDC's former CEO and a pharmacist client. Coincidentally, the client’s son, a robotic expert at Carnegie Mellon University, was involved in creating IAM Robotics. After learning about RDC’s challenges, the team developed a tailored solution. Although speed wasn't the top priority, the robot’s performance of sorting 100 items per hour met RDC’s needs.
Implementing the robot was not without challenges. RDC followed a gradual approach—“climb-walk-run-jumpâ€â€”to minimize risks. IAM provided on-site support and trained operators. Even after training, they continued monitoring the robot via cloud data. RDC now aims to double the robot’s sorting area and integrate it with conveyor systems, reducing manual tasks for operators.
After six months of working with the robot, Ritzman was impressed by the speed of IT integration. Data flowed smoothly between systems, proving the efficiency of the setup. Both Ritzman and Brunnmann believe that robots are ready for companies willing to take the leap. As RDC expands across 10 states, they see mobile robots as a key to scaling operations without additional staff.
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