A world-known, global food wholesaler and distributor needed a massive overhaul to its aging logistics equipment. The combination of out-of-date solutions and sorting inaccuracies brought production and throughput to an all-time low. Working with Murata Machinery, the company automated its case retrieval and eliminated most manual processes and secondary inspections—to increase case sorting and picking throughput by 60%.

This global leader operated as a food wholesaler and distributor, providing third-party logistics (3PL) for manufacturers and retailers in over 520 sites nationwide. Their 3PL services included storage, distribution, and logistics center operations for fresh, dried, chilled, and frozen foods. At a key transfer center, down times and multi-level sorting errors brought throughput to an all-time low—due to failing, end-of-life equipment, manual sorting processes, inventory mismanagement, product damage, and misaligned employee workload.

With a priority on replacing the aging system, Murata quickly designed and installed an AS/RS system of two Uni-Shuttle setups with 21 shuttles each, integrated with a G2P, pick-to-light system. The updated process now:

• Handles multiple tote and case sizes: 17.7” high X 23.62” wide, 13.58” to 32.62” long
• Conveys and automatically stores inventory totes and cases in a high-density storage buffer
• Retrieves and sends inventory totes directly to employees at picking stations
• Uses lights to signal which items to pick from inventory totes and place into order containers
• Automatically routes completed order containers to the packing area
• Returns inventory totes to the high-density storage buffer

With updated automation, the distribution and logistics center saw 60% faster picking and sorting. Storage and retrieval capacity increased to 3,700 cases per hour. Sorting accuracy improved with pick-to-lights feature, and there were reduced sorting errors caused by mechanical inspections.

The facility was able to eliminate the need for secondary sorting and inspects and required fewer personnel to operate. The company partners with Murata to install a similar system to manage receiving and shipping in a second facility.