A Leader in Frozen Food Innovation
Being a global leader in the frozen food industry, specializing in transforming freshly harvested fruits and vegetables into convenient, long-lasting food products. As one of the top companies in the sector, serving nearly every retailer across Europe. Ancra Systems is proud to be a trusted partner in their success.
The Challenges Faced
This processing plant and packing zone are located 150 km away from their frozen warehouse, with operations running 24/7 to process, pack, load, and unload products. During peak periods, particularly the summer and early autumn harvest seasons in Poland, the company needs to process up to 600 pallets a day for several months.
One of the most significant challenges faced is the severe shortage of drivers. Across Europe, the trucking industry faces a shortage of around 400,000 drivers, with over 80,000 of them in Poland alone. To keep up with their daily shuttle transportation needs, 20 trucks are required. However, some days, only 16 trucks are available, leading to major stress in planning and scheduling.
High Operational Costs and Workforce Challenges
The operational costs were also incredibly high. The process involved 45 minutes to load the processed food, followed by a 2-hour drive to the warehouse, 45 minutes for unloading, another 45 minutes to load the stored food, and a 2-hour return trip to the processing plant. The unloading process then had to be repeated. These expenses multiplied by the number of trucks and drivers needed for daily operations quickly added up. And even when there was no return load, they still had to cover the cost of the return trip. Can you imagine the impact this had on their overall efficiency and costs?
Poland also has one of the lowest unemployment rates in the European Union, making it even more challenging to find workers. Competing with other industries offering better working conditions for forklift drivers, as the -18 to -20-degree temperatures in the frozen food sector make it harder to attract and retain skilled operators.
Building Stock, Optimizing Space, and Meeting Demand
Additionally, the seasonal nature of the harvest means they must process enough vegetables to meet sales contracts and customer demand, creating the need for significant stockpiling. At the same time, they must make efficient use of their storage capacity to avoid costly expansions.
The Ancra Systems Solution
After implementing two Ancra Chain Loading and Unloading Systems in their loading/unloading zones and introducing chain track systems in their three dedicated trailers, shuttle flows became much smoother. The efficiency improvements significantly reduced stress in transportation planning, and the fast loading and unloading processes led to higher dock and storage utilization without the need for additional space, adapting perfectly to the high production demands.
Streamlined Operations and Dramatic Time Savings
Now you can decide which chain system to use for unloading, complete the unloading, and then dock at another station to load pre-loaded 26-euro pallets. What used to take 45 minutes for unloading and another 45 minutes for loading is now completed in just 10 minutes for both tasks — as measured.
Scaling Up with Minimal Involvement
The fast, efficient loading processes enables a company to scale operations seamlessly. During peak production periods in late September and early October, when they were producing 3,000 pallets a day, shuttle flows ran smoothly with minimal involvement. Previously, 100% of shuttle operations were dependent on a third-party logistics provider (3PL). Now, only 10% of operations are outsourced, thanks to the streamlined internal processes.
Optimizing Efficiency with SMED
Although the internal logistics from processing to Ancra loading isn’t fully automated yet, forklift drivers still manually feed the system. However, the process runs offline, meaning truck drivers do not have to wait for pallets to be loaded. Using a 'single minute exchange of die' (SMED) approach, the system minimizes downtime and keeps things moving smoothly, reducing truck driver wait times and boosting overall efficiency. Soon, Ancra's loading systems will be fully integrated with an automated conveyor system connecting directly to the storage area, streamlining the entire process.
The Future of Efficient Logistics and Supply Chain
Partnership with Ancra Systems demonstrates how innovation and automation can transform logistical challenges into opportunities for growth. By leveraging Ancra’s ATLS systems and preparing for full automation, is not only addressing current operational needs but also paving the way for a more efficient and sustainable future.
For companies facing similar challenges in their supply chain and logistics, Ancra Systems is ready to help!