Client Background
A 100-year-old tomato sauce manufacturer was facing significant operational challenges in their manual packing line. Their existing process required five operators for palletizing and wrapping, leading to poor attendance, frequent injuries, and low morale.
The Challenge
The manual palletizing process involved lifting 10-25 lb cases all day, which resulted in:
✔ Repetitive motion injuries and workers’ compensation claims
✔ High labor costs and difficulty retaining staff
✔ Low production speed, as additional throughput would require more labor
✔ Safety concerns due to excessive forklift interaction
The company needed a scalable, efficient, and automated solution to improve productivity and employee well-being without increasing headcount.
The Solution
Infinite Motion Industries (IMI) engineered a fully automated robotic palletizing and wrapping system, custom-designed for the facility’s space constraints and aging infrastructure. The solution included:
✅ Robotic Palletizer – Eliminating manual case stacking
✅ Automated Pallet Wrapper – Reducing forklift interaction by 50%
✅ Full Safety Integration – Light curtains & interlocks for operator protection
✅ Custom Fabrication & Programming – Designed for the client’s unique needs
✅ Comprehensive Training & Preventative Maintenance Plan
IMI also navigated significant challenges, including:
⚡ Installing in a 110-year-old building with limited space & outdated utilities
⚡ Minimizing disruption by working evening shifts around production schedules
The Results
🚀 75% Reduction in Labor – The manual workforce required for palletizing dropped from five operators to just one
🚀 20% Increase in Efficiency – Higher throughput without adding labor
🚀 Near-Zero Repetitive Motion Injuries – Improved safety & reduced workers’ comp claims
🚀 Future Scalability – System designed to scale once upstream equipment is upgraded
Key Takeaways
This project highlights IMI’s ability to solve complex manufacturing challenges by:
✅ Implementing the right automation strategy for long-term success
✅ Balancing space limitations, safety, and operational efficiency
✅ Providing ongoing support & training to ensure lasting results
The client was extremely impressed with the outcome, and their investment in automation continues to drive efficiency and safety improvements.
💡 At IMI, we don’t just integrate equipment—we create solutions that transform operations.