Leadec deploys AI-powered cobot solution to automate empties management and improve logistics efficiency

Leadec deploys AI-powered cobot solution to automate empties management and improve logistics efficiency

(IN BRIEF) Leadec has implemented an AI-based pick-and-place solution at its Kölleda site in Germany to automate empties management processes involving small load carriers. The system uses a cobot equipped with 3D vision and AI-powered object recognition software from Vathos to identify, pick, and stack containers with high precision. Initially deployed for two carrier types representing about 30 percent of volume, the solution has proven effective and is now being expanded. By automating repetitive tasks, the system reduces employee workload while improving process consistency and operational reliability. With around 12,000 carriers and 1,800 pallets processed daily, the technology enhances efficiency for automotive logistics operations. Its flexible, hardware-independent design allows easy integration and scalability, supporting Leadec’s plans to extend automation across more facilities and increase the share of automated sorting.

(PRESS RELEASE) STUTTGART, 28-Apr-2026 — /EuropaWire/ — Leadec has introduced an AI-driven pick-and-place system to streamline empties management at its Kölleda site in Germany, marking a significant step toward automating repetitive logistics processes. The new solution combines collaborative robotics with advanced machine vision to enhance efficiency, accuracy, and workplace ergonomics.

At the facility, approximately 12,000 small load carriers (SLCs) are processed daily, requiring sorting, inspection, and preparation for reuse. The newly implemented system features a cobot equipped with a 3D camera and AI-based image recognition, enabling it to identify different container types and their positions regardless of orientation on the conveyor belt. Using a suction gripper, the robot then picks and stacks the carriers onto pallets according to predefined specifications.

The core of the system is AI-powered object recognition software, developed in collaboration with Vathos GmbH. The software was trained using synthetic data representing various SLC types, allowing for highly precise, millimeter-level handling. This approach reduces the need for manual programming and improves adaptability compared to traditional image processing systems.

Initially, the implementation focused on two types of small load carriers, which together represent around 30 percent of the total volume. This phased approach allowed the system to be tested under varying conditions, including both low and high packing densities. Following successful validation, Leadec is now expanding the solution to handle a broader range of carrier types.

The Kölleda site processes around 1,800 pallets of empties each day across two shifts. By automating sorting and stacking tasks, the cobot significantly reduces the physical workload on employees while ensuring consistent process quality and higher operational reliability. For the automotive customer served at the site, this translates into more stable and predictable logistics flows.

A key advantage of the solution lies in its flexibility and ease of integration. The AI-based vision software is hardware-independent and can be incorporated into existing robotics, sensor, and IT environments with minimal setup effort. Its user-friendly interface allows new container variants to be added quickly without complex reprogramming, supporting ongoing scalability.

Leadec selected a collaborative robot to ensure safe interaction between human workers and automation systems. The company is now working toward increasing the share of automatically processed small load carriers to more than half at the Kölleda site, while also preparing to deploy the solution across additional logistics facilities. Further applications of AI-driven automation within its operations are also being explored.

Learn more about the AI-based pick-and-place solution in this video.

About Leadec

Leadec is the leading global service specialist for factories across their entire life cycle and related infrastructure. The company, headquartered in Stuttgart, Germany, generated sales of over 1.35 billion euros in 2025 and employed around 22,500 people in 16 countries. With over 60 years of experience, Leadec supports its customers along the entire production value chain, in more than 900 factories at about 380 sites worldwide.

Leadec’s global services comprise: Install (Installation and Relocation), Automate (Automation & Commissioning, Production IT), Maintain

(Production Equipment Maintenance and Technical Cleaning), Logistics (Value Added Services & Intralogistics), Support (Technical Facility

Management and Infrastructural Facility Management), as well as other local services. The digital business platform Leadec.os offers an end-toend solution which digitizes all service processes across systems.

More about Leadec: www.leadec-services.com

Media Contact:

Corina Hummel
Global Communications Manager
Meitnerstraße 11
70563 Stuttgart
Phone: +49 173 673 2671
corina.hummel@leadec-services.com
www.leadec-services.com

SOURCE: Leadec