From Manual Bottlenecks to Automated Precision: How Integrated Robotics Built Scalable Throughput for a Leader in Sustainable Packaging

The Client: A Leading North American Manufacturer of Sustainable Packaging Solutions

Imagine a primary producer of high-volume plastic parts, a company that serves as a critical link in the global supply chain by providing essential packaging components. Operating out of the American Midwest, they are a cornerstone for industries requiring massive quantities of durable, sustainable plastic products.

Starting in 2014, this manufacturer partnered with FloStor Engineering to modernize their material handling infrastructure. At the time, their facility managed 24 production machines, each outputting approximately 900 pieces per minute. With a case capacity of 1,800 pieces per carton, the facility was a high-speed environment where even minor inefficiencies in the packaging and palletizing stages could lead to significant operational gridlock.

The Challenge

As the demand for sustainable packaging grew, the manufacturer faced a classic scaling challenge: their manual post-production processes could no longer keep pace with the sheer volume of parts being generated by their machines. The existing workflow relied heavily on human intervention, which introduced both physical bottlenecks and quality control risks.

The Bottlenecks of Manual Processes

• Labor-Intensive Post-Production: Once a carton was filled at the production machine, it was discharged to a manual workstation. Here, workers were required to manually un-cuff the inner liners, seal the cases, apply labels, and palletize the finished goods. Wrapping the pallets with plastic sheeting was also a manual floor-level task.
• Logistical Inaccuracies: The operation ran three shifts with approximately 18 workers per shift, yet the manual nature of the sorting led to frequent errors. It was common for cartons destined for one customer to end up on another customer’s pallet, creating significant customer service issues and eroding trust.
• Traffic and Handling Delays: The reliance on human operators to manually remove full pallets and transport them to the warehouse via forklifts or pallet jacks created a stop-and-start momentum. This lack of a continuous, automated flow meant that the facility’s output was often limited by the speed of manual handling rather than the speed of production.

The Solution

Recognizing that their manual systems had reached their limit, the manufacturer sought a fundamental shift in how they moved and managed their products. They needed a partner who could look at the entire operation—from the machine discharge to the final warehouse put-away—and design a cohesive, intelligent system.

FloStor partnered with the manufacturer to engineer an automated material handling system that integrated existing equipment with cutting-edge robotics and autonomous vehicles.

Engineering the Flow: A System Designed for Control

The new solution transformed the facility into a highly controlled, automated environment. The system was designed to take the product directly from the “fill” position and guide it through a series of automated checkpoints without requiring manual touches.

• Integrated Take-Away Conveyor: FloStor developed an automated process that incorporated the client’s existing box formers and bag inserters. A new carton take-away conveyor system was added to bridge the gap between production and final preparation.
• Automated Preparation: As cartons discharge from the fill station, a destination label is automatically applied. The conveyor then transports the cartons to a new “Bag Uncuffer” and Case Sealer, readying them for the final stage of automation.
• Robotic Palletizing: The finished cartons are now robotically palletized across 24 dedicated palletizing stations. As the company grew, this capability was seamlessly extended to 30 robotic stations to accommodate increased volume.
• Intelligent AGV Navigation: To eliminate forklift congestion, the system utilizes Automated Guided Vehicles (AGVs). These vehicles supply empty pallets to the robotic stations and retrieve full pallets, delivering them to automated stretch wrappers to complete the process.

The Power of Integration in Action

FloStor’s role as the integrator was critical in weaving together diverse technologies—robotic arms, automated labeling, case sealers, and AGVs—into a single, unified workflow engine. By automating the transition from the machine to the warehouse, FloStor eliminated the “assembly guesswork” and human error that previously hampered the facility.

The Results

The flexibility and control offered by the automated conveyor and robotic palletizing systems transformed the manufacturer’s production floor into a predictable, high-efficiency powerhouse. By partnering with an experienced system integrator, the client achieved a dramatic shift in both operational accuracy and fiscal performance.

• Dramatic Labor Efficiency: To summarize the return on investment, the headcount required on the production floor dropped from a high of 18 workers per shift to just five.
• Enhanced Accuracy: The automation of labeling and palletizing eliminated the customer service issues caused by misrouted cartons.
• Scalable Growth: The success of the initial integration allowed the client to easily expand their palletizing area by 25% and prompted the implementation of three additional similar systems at other facilities.