Rolflor™ News

Food Distributor Finds Automated Cargo Handling System Reliable,
Cost-Efficient for Heavy, Short-Haul Run

NEW BRIGHTON, PA - With distribution centers in four states and Canada, International Home Foods, Inc. (IHF) is a $2 billion food producer and distributor. Among its leading products are Chef Boyardee^® prepared pastas, Pam^® Cooking Sprays, Franklin Crunch 'n Munch glazed popcorn, Polaner^® fruits spreads and spices, Dennison's^® chili, Ranch Style^® brand beans, ROTEL^® tomatoes and green chilis, Luck's^® Country Style Foods, Gulden's^® mustards, Campfire^® marshmallows and Bumble Bee Seafoods.

One of the most important and busiest facilities for International Home Foods is it's Milton, Pa., distribution center, which ships to grocery stores, brokers and warehouses throughout the U.S. Each year, the facility produces 716,500 pounds of food and snack products.

During an early 1990's expansion at Milton, the company constructed a new, 672,000 square foot distribution center about one mile from the manufacturing operation. Previously, the manufacturing and distribution operations were under a single roof. So while the new center added increased capabilities, the company faced the dilemma of finding a cost-effective system to move cargo between the two buildings.

"There was no way we could cost-effectively haul material between the manufacturing plant and distribution center on a daily basis using conventional van truck hauls," said Jim Runyan, shipping department manager at the Milton facility. "It would tie up the dock and the forklifts, and require considerable manpower."

Instead, the company researched several different automated cargo-handling systems. Among the systems considered - and rejected - was a cable-driven system. "We use wooden pallets extensively, and we found that the cable system chewed up the pallets, making it dirty and dangerous," explained Runyan. He also considered systems that rely on permanently installed rollers in the van bed. The rollers are recessed when not in use, then powered to place either by hydraulics or forced air. The drawback with these systems: They deposit cargo only onto the rollers and not flat onto the dock floor.

Payback in Nine Months

What International Home Foods eventually settled on was the Rolflor^® Cargo Handling System, manufactured by ETA Industries, of New Brighton, PA. The system automatically loads or off loads a full open top or closed van trailer directly to the dock in just four minutes, regardless of cargo type, weight or size.

The patented system features a high-performance polyester fiber belt with a proprietary coating for superior strength and abrasion resistance. The 92-inch-wide belt lies flat on the trailer floor and is powered by hydraulic motors. To load or unload cargo, operators simply activate the motors to wind or unwind the load belt.

International Home Foods purchased five units and installed them on their trailers. The company uses three of it's Rolflor^® systems trucks for three shifts per day, full-time around the clock. Another system truck operates two eight-hour shifts per day. The fifth is used as back-up, and joins the rotation as other trucks undergo maintenance.

"We use the Rolflor^® system as a short-run shuttle service," said Runyan. "We transport approximately 2,100 pallets per day from the manufacturing area to the distribution center, which is a little more than one mile away. The average weight of each pallet is 2,200 pounds."

Runyan said that it takes four minutes for the Rolflor^® system to load or unload a full truck, compared to an average of 20 minutes if it were completed by conventional means. Cargo shifting, which is inherent in conventional loading and unloading, is virtually eliminated by the Rolflor^® Cargo Handling Systems, significantly reducing product damage.

The system works well in trailers up to 53 ft. long, and also is a logical extension for companies with a dock-conveying system or other in-plant automation operations. In addition to palletized cargo, The Rolflor system easily accommodates hazardous waste, baled goods, grains, slip sheeted cargo, produce, refrigerated goods and wood products.

For International Home Foods, the potential for cost savings was the deciding factor when selecting the Rolflor^® System. "The pallets go from the label line areas out onto the rollers straight to the Rolflor system, " explained Runyan. "They're not touched by a forklift operator until they're selected from the warehouse for shipping. By reducing the number of times each pallet is handled, we're able to save the company money."

"We're very conscientious that we get our bang for our buck," continued Runyan. "We documented our increased efficiency and found that we were able to reduce our labor force by lowering the number of shuttle drivers and the number of forklift operators necessary to do the job."

"According to our estimate, the Rolflor^® systems we installed paid for themselves in just nine months on the job."

System Withstands Years of Heavy Use

After six years of continuous, heavy usage, the Rolflor^® system is still performing well for International Home Foods. They're getting a little long in the tooth now, but remain very dependable," said Runyan. "Since we first bought them six and a half years ago, there hasn't been much in the way of equipment down-time, and maintenance costs have been fairly low," said Runyan.

The company out sources maintenance of the Rolflor^® system to nearby Day Equipment Inc., which leases and maintains equipment for local manufacturing facilities.

"I would classify the usage by IHF as very heavy, probably extreme, both in terms of weight and frequency of use," said Jim Tanner, general manager of Day Equipment. "The hauling distance is not very far. But it's a continuous cycle, with each trailer averaging between eight and ten full loads (approximately 462 tons per truck per day) every shift."

Despite this rigorous use, said Tanner, IHF's five Rolflor^® systems have required only routine maintenance to the systems' hydraulics, motors, and belts.

"In a way, the system is self-cleaning," explained Tanner. "Any debris that accumulate onto the belt will drop off and fall to the ground as the belt moves, which helps to limit potential maintenance problems."

"The system itself is outstanding," summed Runyan. "There's no other way we could cost-effectively operate shuttles between the two facilities. The Rolflor^® system works great for us."