How Automation Reworked a Rising Snack Producer

by Mike Welch.

Last updated on Jan 23

Posted on Jan 23, in Palletizing

3 min read time

Robotiq CEO Samuel Bouchard dives into how a regional snack manufacturer leveraged automation to overcome labor challenges, boost efficiency, and scale production. In this conversation with Mike Welch, Channel Sales Manager, they explore the journey to success and the benefits of automation with Robotiq.

Background

This week’s featured Robotiq customer is a regional snack food manufacturer specializing in popcorn products. Based in a remote northern location, their business has experienced exponential growth over the past few years. Despite not yet achieving national distribution, their production volume has surged, straining their existing equipment and resources. To support their growth, they have consistently invested in innovative solutions to support their rapid expansion.

Business Challenges

This customer faced significant challenges tied to their rapid growth and geographic location:

Labor Shortages: Operating in a remote area made it difficult to recruit and retain enough workers for their end-of-line palletizing operations.
Increasing Throughput: Their growing production demand required a reliable and scalable solution to eliminate bottlenecks in their palletizing process.
Equipment Limitations: Early automated systems they implemented in 2021 struggled with heavier payloads, necessitating slower production speeds for some product lines.
Cost and Efficiency Pressures: To sustain their growth and remain competitive, they needed to optimize their operations and ensure a quick return on investment (ROI) for new equipment.

These challenges prompted the company to revisit their automation strategy and explore upgraded solutions to meet their evolving needs.

Why Was Robotiq’s Palletizing Solution a Good Fit?

The company ultimately chose Robotiq’s palletizing solution for several reasons:

Flexibility and Scalability: Our solution’s adaptability allowed the company to transition seamlessly from their older model, lower payload palletizer to one more adapted to their evolving needs. This enabled them to handle heavier payloads (up to 25 kg) with ease while repurposing the older unit for lighter products.
Ease of Use: With intuitive software features like recipe selection and quick SKU setup, the system simplified product changes and modifications. This was especially important for a facility with a small maintenance staff. Their new palletizer used the same software interface, making it seamless for operators to work the new one
High Performance and Reliability: The upgraded system offered enhanced speed and efficiency, reducing downtime and ensuring uninterrupted operations even as production demands grew.
Quick Transition and Minimal Downtime: The transition from the PE10 to the PE20 was completed within a few hours, with minimal disruption to production. The team only had to palletize one load manually during the swap.
Proven Track Record: Robotiq’s standardized and reliable products provided confidence in the long-term ROI and operational stability of their automation investment.

Tips for Automating End-of-Line Palletizing

Start Early: Delaying automation can put you at a disadvantage. Begin integrating automation solutions now to position your business for scalable growth.
Focus on ROI: Evaluate the potential return on investment. With systems like Robotiq’s, customers like this one achieved a ROI within nine months on a three-shift operation.
Prioritize Flexibility: Choose solutions that can adapt to changing production needs, including new SKUs, box sizes, and line configurations.
Leverage Proven Solutions: Opt for standard, field-tested products over custom solutions. Proven systems are less risky and easier to deploy so you get a faster and predictable ROI
Work with Reliable Partners: Collaborate with suppliers who offer quality products and also strong local support to ensure maximum uptime and efficiency.

Automation is no longer a luxury but a necessity for businesses aiming to stay competitive. By investing in scalable, reliable solutions, companies can overcome labor challenges, improve efficiency, and position themselves for long-term success.

Craving more automation success stories about snack manufacturers? Take a look at how Dean Popcorn leverages our solution to transform their operations!