Bettaway Supply Chain Services Adds Second Range of Varied Packaging as Part of Expanding Custom Beverage Distribution Operations


Bettway’s new variety of packaging range includes advanced handling systems that double its beverage packaging production capacity

Automated systems enable mix and match production of various beverage packaging, as well as automated shrink wrapping and palletizing

Bettway’s integrated mixed-pack production line can process 14,400 cases of 24-pack canned or bottled beverages per 8-hour shift

New System Doubles Automated Variety Pack Production Capacity, Supports Greater Role with Monster Beverage for Energy Drink Order Processing and Fulfillment

Speed ​​to market is critical for beverage producers, grocers and big box retailers. These advanced systems provide fast yet flexible production capacity that meets the demanding commitments of our customers.

— Igor Katsman, Vice President, Operations, Bettaway

SOUTH PLAINFIELD, NEW JERSEY, USA, September 19, 2022 / — Bettaway Supply Chain Services has expanded its Garden State Beverage Distribution and Fulfillment Services, launching a second automated “various pack” processing line for the assembly and fulfillment of beverage product orders.

Bettaway, which began approximately 50 years ago as a local soda bottler in Brooklyn, NY, delivering to local businesses, added the new line to its state-of-the-art BevDS beverage handling facility in Piscataway, NJ. Covering 300,000 square feet, the warehouse has 38 dock doors, can store more than 35,000 fully loaded pallets, and supports more than 20 customers handling beverages and other consumer packaged goods (CPG ) food grade.

The new mixed packaging line doubles Bettaway’s production capacity, increasing it to some 14,400 cases of beverages per 8-hour shift, or 72,000 cases over a five-day work week.

John Vaccaro, president of Bettaway, explained that the company had invested in the new processing chain to support an expansion of services for Monster Beverage. The company currently provides warehousing and inventory management for a full line of Monster energy drinks. In its expanded role, Bettaway will provide custom packaging and variety packaging, as well as order management and distribution to stores. Vaccaro also noted that other Bettaway beverage customers will benefit from the expansion, including Powerade and Arizona Beverage Company, makers of AriZona Iced Teas.

The diverse packaging range assembles, packs and labels cases of beverages, whether bottles or cans of various sizes, incorporating custom packaging colors, product logos and graphics. Product moves along automated conveying and handling equipment, quickly assembling packaged cases of various flavors and SKU configurations, exiting through a sophisticated heat-shrink packaging process that seals and secures each case of mixed beverages. A typical variety case is 24 bottles/cans of 3 or 4 different flavors.

Once on the assembly line, the cases enter a computer-controlled mechanical palletizer, which automatically creates precise loads of varied case beverages onto pallets, packs the pallet securely, and prepares them for loading onto trucks.

“Speed ​​to market is critical for beverage producers, grocers and other retailers,” noted Igor Katsman, Bettaway’s vice president of operations. “Meeting this demand requires fast, accurate yet flexible production capability, as well as a proven track record in using automated handling systems technology,” he noted. “These investments provide our customers with the most efficient and responsive co-packing operations in the Northeast.”

Variety-pack orders are typically secured as pallets and trucked to club stores such as Costco and BJ’s as well as regional distribution centers and e-commerce facilities, Katsman explained, adding that the fleet of Dedicated company trucks can be deployed to serve pooled distribution and multi-stop delivery needs.

He pointed out that Bettaway’s approach not only accelerates product speed, but also provides the lowest overall cost for beverage producers. Previously, beverages were shipped to a repacker and then returned to Bettaway. In-house automated variety packing lines eliminate the cost and time associated with this intermediate processing step.

In addition to pallet deliveries to stores, Bettaway also has extensive e-commerce order fulfillment capabilities. The company is integrated with various multi-client e-commerce platforms as well as proprietary beverage producer order management systems. E-commerce orders are typically 4-packs of drinks shipped directly to consumers. Today, Bettaway’s systems and teams process and ship hundreds of orders per week.

The company also supports orders through Amazon, assembling and consolidating shipments, then trucking them to Amazon warehouses for later fulfillment.

Bettaway also provides other third parties Logistics services. These include inbound trucking of products from beverage plants to Bettaway facilities, receiving and unloading, inventory management, new handling, assembly and delivery of orders through Bettaway’s dedicated fleet as well only with trusted third-party trucking providers. The company’s services include local drayage to truck shipping containers from the ports of New York and New Jersey. Bettaway also operates one of the nation’s largest pallet supply, distribution and asset management networks, providing pallets and a suite of associated services to thousands of businesses from more than 400 depots in across the United States.

About Bettaway Supply Chain Services and BevDS: Bettaway, based in South Plainfield, New Jersey, is an integrated material handling, transportation and supply chain management company. Bettaway is an industry leader in pallet management solutions, offering a managed services program based on a network of facilities and a centralized suite of pallet services. The company also provides quality transportation with its own dedicated fleets on the east and west coasts and its nationwide 3PL network. Value-added services include a full warehouse operation with a range of diverse packaging, e-commerce fulfillment and distribution management for beverages and other CPG products, and supply chain consulting services. ‘supply. Visit us at

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