Imagine this: You’re inside a bustling food manufacturer’s warehouse and the aroma of newly produced goods wafts through the air as workers navigate controlled chaos, racing against tight delivery windows to get product to customers. Then it happens — a bottleneck at the loading docks. Trailers sit idle as product piles up and the clock ticks mercilessly. Each passing minute of unproductivity burns through millions of dollars in lost revenue. In this high stakes scenario, what’s a manufacturer to do?
In the fast-paced world of manufacturing and distribution, speed to market and minimal downtime are paramount. Traditional warehouse operations, especially trailer loading operations, have long been plagued by inefficiencies. One of the most significant issues is the long loading times. Sometimes it can be as much as three hours to load a single trailer. Time-intensive tasks like this not only slow down the overall distribution and fulfilment process but can increase manual labor costs.
This inefficiency can be mitigated through the implementation of robotics and automation. The concept of automation in industrial and manufacturing operations has been around for quite some time. But it is now gaining increased attention due to the current labor landscape characterized by significant labor shortages, a growing number of retirees compared to new workers entering the workforce and an increasing need for workers with specialized skills.
The dependence in manufacturing on high manual labor hours introduces variability and the potential for human error, exposing companies to higher risks for safety incidents that further complicate the distribution process. Additionally, manufacturers frequently confront the challenge of securing — or constructing — a facility that not only offers ample dock door access and sufficient capacity to manage large volumes of product but also provides a flexible layout. This adaptability is crucial, as it allows manufacturers to easily repurpose the space for evolving operational needs or alternative future uses.
Automation is positively changing operations across industries. As a prime example, our team at Burns & McDonnell, in partnership with a trusted equipment vendor, designed and installed an advanced automated bulk trailer loading system for a major snack food manufacturer. This innovative solution dramatically enhanced efficiency at one of its key facilities by slashing load times for a single trailer from three hours to minutes.
How the Pilot Automation Works
The system installed integrated with the manufacturer’s existing automated storage and retrieval system, enabling the assembly of custom orders for distribution centers across the region. Key features of the advanced equipment included:
- Pick-and-place robots
- Stretch wrappers
- Trolley systems
- Pallet conveyors
- Case elevators
- Modified trailer loading conveyor
Necessary additions and upgrades needed for seamless equipment integration included:
- Trailer Modifications
- Base pockets were added to accommodate the bulk loader forks.
- Warehouse Dock Enhancements
- Hydraulic trailer lift was installed for better dock alignment.
- Guiding rails were included so that trailers could be positioned accurately for optimal loading.
- Automated Dock Door System
- Bulk-loading conveyor was upgraded with an automated system that opens and closes dock doors as needed.
Benefits of Adding Automation
The pilot automation significantly boosted productivity, reduced the need for manual labor and allowed operations to be remotely monitored through a series of strategically placed cameras that provide real-time oversight and control. Designed for versatility, the system can handle various cargo types and loading requirements, optimizing flexibility and efficiency in warehouse operations and accelerating speed to market.
Additionally, the pilot program demonstrated substantial improvements in throughput enabling the manufacturer to gain a competitive advantage in order fulfillment speed. Faster load times, like those realized during the pilot, means manufacturers can operate in a smaller space footprint, because fewer dock doors are needed, allowing operators to optimize warehouse real estate, lower operational costs and repurpose space for other needs.
Finally, increased automation during the pilot helped enhance workforce roles and safety. By taking over repetitive and physically demanding tasks, the system allowed workers to focus on more strategic and high-value tasks and activities. This not only helped improve job satisfaction but also reduced the risk of workplace injuries associated with manual loading.
What’s Next?
Manufacturers should view automation not as a cost center, but as the foundation for market leadership in an era where supply chain velocity equals competitive dominance. Automated bulk trailer loading systems can be applied across various manufacturing and industrial sectors, including food, beverage, consumer products, life sciences and more, providing an effective solution to common warehouse challenges. This technology paves the way for increased productivity, cost savings and enhanced sustainability.
Continuous innovation and collaboration with industry partners can help drive automated distribution and fulfillment warehouse operations forward. Learn how to make automation work for your operation.
