From Robot Failure to Automation Success: How FloStor Rescued La Tortilla’s Factory’s Packaging Vision

The Client: La Tortilla Factory

La Tortilla Factory is a renowned food manufacturer specializing in premium tortilla products. Founded in 1977, the company revolutionized the industry with innovations like low-carb tortillas and has grown from serving local California grocers to becoming a national brand with products in major food stores across the country. Their commitment to flavorful, health-conscious products, including organic and extra virgin olive oil product lines, has positioned them as a leader in the tortilla market.

The Challenge

La Tortilla Factory faced a critical automation hurdle that threatened their production expansion plans. After working directly with a Bay Area robot manufacturer who had conducted seemingly successful packaging tests at their facility, La Tortilla Factory was ready to implement an automated packaging solution for their tortillas. The initial tests had shown promise, with the robot appearing to handle the tortillas effectively.

However, implementing a robotic system isn’t as simple as purchasing a robot and plugging it in. Robots are just one component of a complex, integrated system. La Tortilla Factory needed someone to coordinate the entire project – designing how empty trays and cases would be delivered to the robot, ensuring all components worked together seamlessly, and meeting specific production rates for various tortilla products and packaging configurations.

This is where the value of a material handling systems integrator became apparent. While La Tortilla Factory had expertise in making excellent tortillas, and the robot manufacturer understood their specific robot, neither had the specialized knowledge to create a complete, functioning automated packaging system that would reliably perform in a real production environment.

The Solution

The Integrator’s Crucial Role

FloStor Engineering stepped in as the material handling systems integrator – essentially serving as the architect and general contractor for the entire automation project. As an integrator, FloStor’s responsibility was to design and implement a customized solution based on La Tortilla Factory’s specific requirements to meet their production goals.

A material handling systems integrator provides unbiased advice on what technologies are best suited for a business’s challenges, goals, and product details. They look at the whole process, helping build a system that not only deals with installing single pieces of equipment but prepares the business for growth.

The Initial Approach

Working collaboratively with both La Tortilla Factory and the robot manufacturer, FloStor developed detailed specifications covering production rates and various “recipes” for different carton sizes and tortilla SKUs. With agreement from all parties, an order was placed for three identical robotic cells.

The plan was methodical: build and test the first cell at FloStor’s Hayward facility before deploying all three at La Tortilla Factory. FloStor constructed the mounting frame according to the robot manufacturer’s specifications and brought in the recommended controls house to program the robot.

When Technology Fails: The Integrator’s Problem-Solving Value

This is where the project encountered significant challenges – challenges that highlight why working with an experienced systems integrator is invaluable:

• Programming Issues: Almost immediately, the controls programmer discovered the robot had a different operating system than expected, creating compatibility problems.
• Performance Problems: Even after resolving the initial programming hurdle, the robot exhibited concerning behaviors, including shaking after transferring packaged tortillas.
• Rate Failure: The robot couldn’t achieve the specified production rate – a critical requirement for La Tortilla Factory’s operations.
• Reliability Concerns: The end-of-arm tooling (the “hand” of the robot that actually handles the product) wasn’t robust enough for continuous operation, frequently dropping tortillas.
• Personnel Changes: Key people from the robot manufacturer involved with the project resigned, further complicating the situation.

These issues represent common risks in automation projects. Without a systems integrator managing the process, La Tortilla Factory would have been left with expensive, non-functional equipment and no clear path forward.

The Pivot: Finding the Right Solution

Rather than continuing down a problematic path, FloStor took decisive action to ensure La Tortilla Factory received a system that actually worked. This demonstrates how a material handling systems integrator is accountable for any unplanned disruptions.

FloStor consulted with HCM, a trusted robot integration partner from previous successful projects. After thorough evaluation, they determined that a FANUC robot would be better suited for the application. This illustrates how integrators can recommend trustworthy brands and equipment that works well with others and will efficiently process the types of items a facility handles.

HCM, located in Chicago, conducted rigorous testing with the FANUC robot to verify both rate and reliability before proceeding – a critical step that the original robot manufacturer had apparently skipped or inadequately performed.

The new solution required a more robust frame to support the FANUC robot, which FloStor promptly built. Throughout this process, FloStor maintained transparent communication with La Tortilla Factory, keeping them informed of developments and challenges. This transparency is another hallmark of a good integrator, who serves as the single point of contact throughout each phase of a project.

Testing and Implementation

Once the new robotic cell was assembled at FloStor’s facility, La Tortilla Factory was invited to witness capability tests. The demonstration proved successful, with the FANUC robot meeting both rate and reliability requirements. With the client’s approval, FloStor proceeded to install all three systems at La Tortilla Factory’s production facility.

The final step involved the complex task of returning the original robots and resolving payment issues with the original robot manufacturer and controls house – a potentially litigious situation that FloStor handled on behalf of La Tortilla Factory. This further demonstrates how integrators shield clients from the day-to-day questions and problems from subcontractors, allowing them to focus on running their business.

The Value of a Systems Integrator

This case study powerfully illustrates why companies like La Tortilla Factory benefit from working with material handling systems integrators like FloStor:

• Expertise Across Technologies: FloStor wasn’t tied to a single robot brand or technology, allowing them to pivot to a better solution when the original plan failed.
• Risk Management: When the initial robot proved inadequate, FloStor absorbed much of the project risk and found an alternative solution rather than delivering a system that didn’t meet requirements.
• Project Management: FloStor coordinated between multiple vendors (robot manufacturers, controls programmers, etc.) and handled the complex return process when equipment didn’t perform.
• Testing and Validation: By thoroughly testing the solution before final implementation, FloStor ensured La Tortilla Factory received a system that actually worked in their production environment.
• Single Point of Responsibility: Throughout the challenges, La Tortilla Factory had one partner to work with rather than trying to mediate between multiple vendors pointing fingers at each other.

For La Tortilla Factory, this project ultimately delivered the automated packaging solution they needed, despite the significant hurdles encountered along the way. By partnering with FloStor as their systems integrator, they were able to navigate the complex world of automation and achieve their production goals without becoming experts in robotics themselves.

This case demonstrates why material handling systems integration is crucial for successful automation projects – especially for companies whose core expertise lies in their products rather than in automation technology.