This co-packer had begun a multi-phase facility expansion project which would result in two automated packaging lines, intended to double their current production volumes by the end of 2024. The first phase of the project included an overhaul of their current line to handle new upstream fillers. Manual case erecting, packing, and sealing funtions had been replaced with an automated Pearson box former, handpack station, and case sealer. Unfortunately, their aging palletizer was at maximum capacity running 14cpm, while needing to support 24cpm as production ramped up.
Due to the challenges and hefty cost of sourcing and retaining workers, plus the weight of the cases, manual labor was not an option. And, with so many logistics, fluctuating timelines, and anticipated layout changes, installing a custom robotic palletizer was not ideal until the project was more clearly developed. The customer needed an interim palletizing solution that could install quickly and be relocated within their facility if necessary.