AUTOMATION & ROBOTICS
new platform for us, the system architecture was intuitive and we didn’t need complex co-integration. Beckhoff’s support made the transition smooth.”
Remote deployment was a major advantage.
Ocado’s operations span multiple continents, and its engineering teams must be able to update and support machines worldwide without constant travel. “Remote software deployment is key for us,”
continues Calderon Santana. “With Beckhoff, we can push updates and make adjustments from the UK to a site in Japan or the U.S. This remote capability is crucial for reducing downtime and ensuring consistency across every facility.” The TwinCAT software platform enables
integration into CI/CD pipelines and allows validated operating system updates, PLC code and safety logic changes to be administered centrally and automatically rolled out to globally deployed assets.
COLLABORATION AND INTEGRATION The partnership began when Ocado’s engineers visited Beckhoff’s UK technology centre to explore live applications and test sample units. From there, Ocado tested Beckhoff hardware and software in-house before standardising on the platform for the AFL. “The Beckhoff team was proactive from the
start,” says Calderon Santana. “They took the time to understand what we were trying to achieve and provided expert guidance on how to get the best out of their technology. That level of engagement has continued as we look to roll out Beckhoff technology in other machines.” Beckhoff engineers visited Ocado sites
to observe the AFL in action and ensure optimal configuration. However, Ocado’s internal engineering team handled most of the implementation directly, a testament to the ease of integration. “It was straightforward to adopt,” adds Calderon Santana. “Even though it was a
SAFETY AND RELIABILITY AT SCALE In high-throughput facilities, where tens of thousands of orders move each day, safety and uptime are non-negotiable. Beckhoff’s TwinSAFE system consolidates all safety functions, from emergency stops to interlocks, into the same EtherCAT network that runs standard I/O, simplifying wiring and reducing latency. “With TwinSAFE, safety isn’t a bolt-on feature,
it’s fully integrated,” explains McEwan. “The TwinSAFE logic is part of the same TwinCAT project environment meaning incorporating functional safety into the machines is seamless. This reduces programming and integration time and improves diagnostics during both commissioning and normal operation.” For Ocado, reliability is critical. A breakdown
in the AFL could delay van departures and disrupt delivery commitments. The Beckhoff hardware and software ensures continuous operation and the Ocado equipment can run all day with minimal intervention. Combined with predictive monitoring via Ocado’s own analytics tools, the result is a resilient, self-optimising system. EtherCAT’s efficient bandwidth utilisation makes it ideal for collecting large volumes of data to support predictive maintenance strategies. Because all EtherCAT devices on the
network are typically updated within a single frame, ample bandwidth remains available for continuous data acquisition on the fieldbus. Beckhoff controllers further enhance this capability with high memory capacity (RAM) and large, removable media drives, enabling data to be stored and analysed locally at the edge.
CYBERSECURITY AND CONNECTIVITY Given the scale and global reach of Ocado’s automation network, cybersecurity is a key consideration for any new technology. “Cybersecurity is incredibly important for us,” says Calderon Santana. “Every piece of
technology that enters our system must meet a very high bar. Beckhoff’s platform integrates well into our internal cybersecurity framework, which is modular and designed to manage risk across all control systems.” While Ocado’s cybersecurity tools are
developed internally, Beckhoff’s open architecture ensures compatibility with Ocado’s monitoring and traceability systems, enabling secure data exchange between the AFL and the wider warehouse management network.
EMPOWERING PEOPLE The success of the AFL means Beckhoff and Ocado are already working on future Ocado machines under development within the business. “Our strategy is to build flexibility into every
control system we design,” says Calderon Santana. “Beckhoff enables that. Every new machine we’re developing is assessed with Beckhoff technology in mind, because it gives us the scalability we need.” Bailey adds that Beckhoff’s involvement goes
beyond hardware: “The team has been genuinely engaged in supporting our growth, not just supplying technology but helping us connect with others and explore new ideas. It’s a true partnership.” Looking ahead, Ocado plans to expand its
automation technology beyond grocery, applying the same innovations to pharmaceuticals and clothing, among other product areas. The AFL, equipped with Beckhoff technology, provides a modular foundation for these ventures. “Beckhoff’s technology helps us deliver on our
core promise to customers, accuracy, reliability and on-time delivery,” concludes Bailey. “It’s a critical part of how we make convenient and great-value online grocery deliveries not just possible, but sustainable.”
Beckhoff
www.beckhoff.co.uk FACTORY&HANDLINGSOLUTIONS | APRIL 2026 27
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