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CPC International Case Study | Food & Beverage

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Expanding Apple Production with Automated Carton Handling and Palletizing

CPC International Apple Company, a privately held family-owned fruit wholesaler, packages and sells several varieties of apples around the globe. Needing to increase throughput while also facing labor challenges in their industry, CPC sought a new packing model for their facility. The goal was to turn three packing lines into a single system and expand the variety and volume of apples the company could process. RH Brown’s system integration team, which is now a Bastian Solutions regional office in the Pacific Northwest, worked with CPC to help turn this concept into reality

The new system maintains the integrity of every carton, providing the quality CPC International expects for each shipment. "At the rate we're packing today, you can't do it the old-school way.” Explained Jon Alegria, President & Owner of CPC International. “In the old system, we were processing probably 700-800 boxes an hour. With this [new] system, we're now at 2,500 to 3,000 boxes an hour.” The new automated solution triples production rates while maintaining staffing levels and enabling efficient, uniform handling of 40 to 60 SKUs per variety. 

 

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CPC International

Key Technologies

  • Hytrol Conveyor - Over two miles of conveyor systems for efficient material handling. 
  • EZLogic controls - For controlling accumulation lanes. 
  • Warehouse control software - For coordinating equipment, customizable controls, and reporting tools. 
  • Automated palletizing - Including machine application of corner boards, strapping, and shrink wrapping. 
 

Results

This project included tying in CPC’s existing data systems and enabling a fully automated operation, adding significant improvements in efficiency and capacity. 

  • Increased throughput by over 250%, from 700-800 to 2500-3000 boxes per hour.
  • Increased apple processing capacity to 350,000 apples per minute.
  • Maintained current staffing levels despite increased production.
  • Achieved 99.9% accuracy in carton handling.
  • Tripled overall production rates.
  • Improved packaging uniformity and quality.
  • Enabled efficient and automated handling of 40 to 60 SKUs per apple variety.
 


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