From Cartons to Customers: Engineering Predictable Flow in High-Speed Distribution

The Client: International Paper

International Paper’s beverage packaging operation in Turlock, California supports high-volume carton production and distribution across the western United States and export channels. The facility’s role requires fast, accurate order changeovers and consistently reliable outbound flow.

To maintain service goals, the operation needed a more dependable handling system that could keep pace with rising speed and sorting demands.

The Challenge

• Palletizing Capacity Limit: A legacy gantry-style palletizer could not keep pace with required throughput and rapid order changes.
• Merge-Line Backups: Converging carton flows repeatedly bottlenecked, creating stop-start operation and output instability.
• Frequent Jam Intervention: Multiple jam-prone points required line stops and manual clearing, reducing productive run time.
• Outdated Sortation Method: Reflective-tape sorting technology lacked the speed and precision needed for modern volume conditions.
• Reliability Gap to Shipping Targets: The combined effect of delays and misroutes threatened shipment consistency and operating efficiency.

“We were just not achieving the kinds of reliability levels needed to meet our shipping goals.” – Ron Young, Maintenance Team Leader

The Solution

FloStor engineered and delivered a turnkey material handling modernization that integrated recirculating sortation, automated palletizing, and software-directed controls into one coordinated process. The objective was to stabilize flow, improve routing accuracy, and eliminate jam-driven interruptions.

The new architecture connected seven sealing lines to a mezzanine-level recirculating loop, allowing continuous carton movement even during rapid destination changeovers.

Systems Used

• Recirculating Sortation Conveyor: Mezzanine-level loop maintained controlled product circulation and reduced congestion during lane transitions.
• HMI-Driven Batch Changeover Controls: Operators entered changeovers via interface without stopping line flow.
• Scanner-Based Lane Assignment: Barcode-read carton identification routed product to four palletizer lanes plus a dedicated exception lane.
• Automatic Palletizers: Sorted cartons were palletized into stable shipment-ready unit loads at higher reliability levels.
• Automated Transfer Car and Stretch Wrap Integration: Pallets moved from palletizer discharge to wrap and final staging with optional inspection pause logic.
• Chain-Drive to Gravity Shipping Staging: Final handoff prepared wrapped pallets for dock-side forklift pickup with improved sequence control.

The Power of Integration in Action

FloStor’s integrator role unified software, controls, conveyors, palletizers, and electrical architecture under one operating logic. This eliminated disconnected vendor interfaces and provided International Paper with a single coordinated execution model for high-speed carton flow.

The recirculating design absorbed short-term downstream variation while keeping upstream production moving, reducing jam frequency and improving shipment consistency.

“After a lengthy selection process, our Engineering Group selected FloStor based on their design concept and their ability to do the job. FloStor exceeded our expectations.” – Ron Young, Maintenance Team Leader

The Results

International Paper transformed a disruption-prone handling process into a more reliable, high-accuracy distribution flow. The modernized system improved operational continuity and reduced the performance drag of frequent stops and manual intervention.

With integrated controls and smarter sortation, the facility achieved stronger shipment confidence while lowering operational burden tied to downtime and maintenance.

Why This Worked

This implementation succeeded because International Paper and FloStor redesigned the full distribution sequence rather than patching isolated failure points. Flow buffering, sort intelligence, and automated pallet handling were engineered to work as one system.

• Recirculating Buffer Logic: Continuous loop design absorbed variation and prevented upstream stoppage during changeovers.
• Turnkey Integration Accountability: One integrator coordinated controls, hardware, and software for faster issue resolution and cleaner commissioning.
• Automated Path Segmentation: Dedicated exception and palletizer lanes protected standard flow while preserving handling flexibility.
• Reliability-First Engineering: Jam-prone legacy points were replaced with modern, serviceable components built for sustained high-speed use.

Related Services

• System Integration and Controls Engineering
• High-Speed Conveyor and Sortation Architecture
• Automated Palletizing and Transfer Workflow Design
• Turnkey Distribution Modernization and Lifecycle Support