Blanca Potato, a Colorado-based grower, processes approximately 2.2 million 50-pound bags of potatoes annually for North American and international markets. In an effort to optimize operations, the company has introduced automated material handling systems, including robotic equipment and conveyors, to replace labor-intensive processes.
However, the transition faced challenges when pallets began failing, leading to distribution disruptions. Rodney Smith, general manager of Blanca Potato, noted that the company had relied on manual processes for years. "Getting the potatoes into bags and crates, then putting them onto pallets has not changed a whole lot over the years," Smith stated.
The automation aimed to streamline tasks such as stacking and moving packaged potatoes for shrink-wrapping, storage, and shipping. "Now, through use the of robotics and automated material handling systems, robotic arms are picking up packages and [loading] them precisely on pallets," Smith explained.
Despite these advancements, the existing wooden pallets failed to withstand the new system, causing frequent shutdowns. Smith reported up to 20 system halts daily due to broken pallets, negating the benefits of automation and affecting delivery schedules.
Seeking a solution, Blanca Potato collaborated with Peco Pallet, a rental company known for its durable wood block pallets. Peco's closed-loop pallet pool system ensures that pallets are inspected, cleaned, and repaired regularly. "Peco provided pallets of the proper grade that can [stand] up to the rigors of the product and the automated material handling systems," Smith said.
Since adopting Peco pallets, Blanca Potato's pallet failure rate has significantly decreased, with Smith estimating a rejection rate of less than 1% from the 50,000 pallets used annually. The integration of automation and upgraded pallet systems has resulted in reduced labor costs, fewer pallet failures, improved customer response, and enhanced satisfaction.
Source: DC Velocity