The Impact of Material Handling Automation on McDougall & Sons' Cherry Production

Trever Hofman | 27 June 2024

From orchard to market: See how advanced automation and data analytics from RH Brown, now proudly part of Bastian Solutions, transformed a fourth-generation family business.

Wenatchee, Washington, may be known as the "Apple Capital of the World," but is also renowned for its bountiful sweet cherry orchards. McDougall & Sons, a fourth-generation family-owned business, has been growing, processing, and distributing cherries and other tree fruits for decades. With Washington state producing millions of pounds of cherries annually, meeting the demand for fresh and high-quality sweet cherries is no small achievement. McDougall & Sons faced the challenge of increasing processing rates, managing peak capacity, and balancing production across multiple lines. To meet the demand for customers in both domestic and export markets, they partnered with RH Brown. Their collaboration led to significant improvements through advanced material handling automation, warehouse control software, and data analytics, transforming McDougall & Sons' operations and efficiency.

 

Overcoming Operational Hurdles and Industry Shift

McDougall & Sons faced several operational challenges. Increasing processing rates was needed to keep up with the high demand for their premium sweet cherries. Managing capacity during peak times required a precise and efficient approach to handle the influx of cherries being harvested. Additionally, balancing production between two cherry lines posed difficulties, demanding seamless coordination to maintain consistency and quality. Another critical aspect was improving the visibility of the cherry production process, which was essential for accurate and real-time grower payments.

McDougall & Sons recognized the need to adapt to new packaging preferences as the fruit industry evolved. The market shifted from bulk cartons to smaller consumer packaging, such as small bags and clamshells. Lee Coonfield, Plant Technology Manager, understood the implications of these changes and saw the necessity for a new solution to meet these industry demands. The traditional methods were no longer sufficient to efficiently handle the complexities and increased volume. This realization prompted the search for an innovative approach to streamline operations and maintain McDougall & Sons' commitment to quality.

Processing sweet cherries presents unique challenges with the short growing season and intense, demanding work schedule. “We run two 10-hour shifts, seven days a week for almost 60 days straight,” explains Coonfield saying that cherry season “is one of the biggest grinds imaginable,” necessitating a seamless and well-coordinated approach to maintain the high standards McDougall & Sons is known for.

Coonfield’s commitment to delivering top-quality sweet cherries drives every aspect of the operation. He emphasizes the importance of not leaving any step to chance, ensuring that every process is meticulously managed, from “harvest to storage to packing, to provide consumers with a great eating experience.” This dedication drove the need for advanced automation and innovative solutions to overcome operational challenges during peak season.

RH Brown & Bastian Solutions: Material Handing Automation Integrator Partners

To address these challenges, McDougall & Sons turned to RH Brown As a leading integrator of automated material handling solutions, warehouse control software, and data analytics, the team  was well-equipped to provide the necessary advancements.

The tailored solution featured three primary components:

Automated Material Handling

• The introduction of advanced automation streamlined carton movement, significantly reducing manual labor. This automation ensured a smoother, more efficient process, minimizing the potential for errors and delays.

Warehouse Control Software

• The new warehouse control software allowed for precise management of production lines. This system provided real-time insights into processing operations, facilitating quick decision-making and enhancing overall efficiency.

Data Analytics

• Processing cherries and tracking grower payments required robust data analytics capabilities. These analytics provide valuable information about the production processes, enabling better accuracy and speed in carton handling. Coonfield noted the impact of this feature, stating, “It has enabled our accounting department to have a concrete platform to stand on when accounting for cartons. Also, the system handles cartons at more than twice the speed at which our old system did and with 99.9% accuracy. Without this feature, we would not have been able to run at all.”

Impact and Results

Implementing the tailored solution significantly improved McDougall & Sons' operations. The most notable achievements include a 130% increase in throughput, a remarkable enhancement that enabled the company to meet and exceed its production goals. Specifically, one production line now processes an average of 20 tons of cherries per hour, while the second line handles 17 tons per hour. Additionally, each production line can process an impressive 100 cases per minute, a testament to the efficiency gains realized through the new system.

Coonfield expresses his satisfaction with the partnership, highlighting RH Brown’s ' critical role in their success. “RH Brown [now part of Bastian Solutions] listens. It’s one of the most critical attributes of any partnership,” Coonfield remarked, underscoring the importance of effective communication and collaboration in achieving these outstanding results. The enhancements streamlined McDougall & Sons' operations and reinforced their commitment to delivering top-quality cherries to consumers.

If you want to transform your operations and achieve significant efficiency improvements like McDougall & Sons, consider partnering with RH Brown, now part of Bastian Solutions. With expertise in automated material handling solutions, warehouse control software, and data analytics, we’re ready to help you meet your unique challenges and optimize your processes.

Contact our team today for a consultation and discover how tailored automation can grow your business.

RH Brown, founded in 1911, is a fourth-generation family-owned business with offices in Seattle, Washington and Portland, Oregon. RH Brown, together in partnership with Bastian Solutions, a Toyota Automated Logistics company, is a premier provider of material handling solutions in the Pacific Northwest and beyond. We are excited to share that later this year, the RH Brown systems integration team will be rebranding as Bastian Solutions. This change marks a significant milestone in our journey together and reflects our commitment to providing companies with the highest level of service and innovation in material handling and automated solutions.

Author: Trever Hofman