THE CUSTOMER

The world's largest multinational paint manufacturer, specializing in decorative paints, industrial coatings, wall coverings, waterproofing solutions, adhesives, has automated its inbound operations using four of Ancra’s stationary unloading systems — the LoadRunner.

CHALLENGES

While many companies adopt loading dock automation to improve efficiency, reduce labour and equipment costs, or enhance safety, this multinational paint manufacturer had plans to implement maximum automation in all areas. The company decided to install the LoadRunner unloading equipment by Ancra so that they could carry out the unloading process without any manual processes and reduce the manpower needed. They had to unload almost 80-90 32 feet container trucks which they are doing in 8-10 hrs using the load runner which otherwise would have taken more than 20 hrs for manual unloading.

To address these challenges and ensure a reliable, consistent unloading process, they have chosen to automate with Ancra’s LoadRunner systems.

THE SOLUTIONS

To address their challenges, the company implemented Ancra’s LoadRunner system at two key locations, each equipped with four stationary unloading units.

The LoadRunner combines two advanced conveying technologies:

• A load skate system, utilizing long, liftable aluminium and steel forks with rollers to easily move pallets in and out of trailers.
• A chain conveyor system, designed with low-friction, wear-resistant aluminium profiles to seamlessly transfer pallets between conveyor belts.

The LoadRunner is perfectly suited for unloading pelletized paints, with a standard pallet size of 1,000mm x 1,200mm in Short-Side Leading (SSL) orientation.

This smart, cost-effective solution ensures reliable, hands-free unloading, streamlining the company’s inbound operations and eliminating dependency on labour.

RESULT AND IMPACT

By implementing Ancra’s LoadRunner system, the company has successfully transformed its inbound operations, achieving a reliable and consistent material flow without being dependent on staff availability at the dock.

Key results include:

• Time efficiency: The automation reduced unloading times from 30–45 minutes to just a few minutes per container, enabling the company to complete three loads per dock.
• Labor independence: The system ensures smooth, continuous operations even during labour shortages, eliminating the risk of delays due to workforce availability.
• Operational consistency: With hands-free unloading, the company now enjoys uninterrupted and streamlined logistics, significantly improving overall productivity and efficiency.

This Ancra’s ATLS Solution has not only optimized the unloading process but also contributed to a more agile, cost-effective inbound operation, positioning the company for future growth and success.