Walmart’s 98% automated distribution centers use AI to cut food waste

Walmart has deployed AI-powered distribution centers across multiple states to optimize fresh food inventory management and reduce waste that erodes profit margins. The retail giant’s automated facilities use machine learning algorithms to predict demand by analyzing external factors like weather patterns and sporting events, moving beyond traditional sales-based forecasting to create more strategic pricing and inventory decisions.

What you should know: Walmart’s high-tech distribution centers represent a significant shift from traditional inventory management to AI-driven supply chain optimization.

• Over the past four years, Walmart has constructed automated grocery distribution centers in California, South Carolina, and Texas that use robotics and AI to process fresh vegetables and perishables faster than conventional facilities.
• The Wellford, South Carolina facility spans 725,000 square feet and operates at 98% automation, autonomously processing deliveries and shipping goods to 180 stores across five states.
• AI algorithms create “perfect pallets” by determining optimal placement for each food item, calculating quantities needed, and configuring loads to maximize space while preventing damage to fragile items like eggs.

How it works: Walmart’s AI systems integrate multiple data sources to make real-time inventory and logistics decisions.

• Predictive AI in Costa Rica maps optimal delivery routes for pineapples and root vegetables, while Mexico operations use AI-enabled inventory tools that automatically reroute overstocked goods to stores with lower supply levels.
• Machine learning models can distinguish regional demand patterns, such as sending extra shovels to Arizona stores before an unexpected snowstorm while maintaining normal inventory levels in Maine where snow is common.
• Algorithms consider individual store layouts when organizing pallets, placing items in sequences that make it easier for associates to stock shelves efficiently.

The big picture: AI is helping Walmart transform supply chain management from reactive to predictive, addressing the fundamental challenge of food waste in an industry known for razor-thin margins.

• “There’s a lot of data in retail and you can monetize it if you can actually take action on it,” said Yasemin Gunay, a managing director at Boston Consulting Group, a global consulting firm.
• The technology enables more strategic pricing through targeted promotions based on stock levels and local sales trends, moving beyond historical sales data to incorporate external variables.

What they’re saying: Walmart executives emphasize that AI implementation extends beyond experimental phases into operational reality.

• “You want to reduce the buffer inventory,” said Indira Uppuluri, Walmart’s senior vice president of supply chain technology, explaining how AI helps forecast demand to lower costs associated with excess inventory.
• “There are multiple places where today we have generative AI in production being leveraged by our associates,” Uppuluri added. “It’s not just a proof of concept.”
• James Bright, general manager of the Wellford facility, noted that “a lot of use of AI is in the background as we continue to automate our supply chain,” including incorporating feedback from store associates to refine algorithms.