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Case Studies

Deanan Gourmet Popcorn

Family-owned and operated Deanan Popcorn scales up operations with Robotiq Palletizing Solution.

1/2 pallet

Footprint

3-Day

Install

2 to 1

Conveyor to palletizing option

About Deanan Gourmet Popcorn

Deanan Gourmet Popcorn is a family-owned and operated business known for producing high-quality popcorn products. Established in 1979, the company has a strong legacy in the gourmet snack industry, originally starting as a way to support local fundraising efforts for schools and organizations. Over the years, Deanan has grown its product line to include a variety of flavored popcorn options. As Deanan Gourmet Popcorn continues to expand, the company is strategically investing in scaling up its operations to meet growing demand.

Company Overview

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Step 1 - Box dimensions, weight and orientation

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Step 1 - Box dimensions, weight and orientation

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Step 1 - Box dimensions, weight and orientation

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It doesn't have the big cage around it, and the footprint is so small, like it's half a pallet, and it's movable. Those two things sold me right away. On top of that, it had a third of the budget that all the other robot companies had proposed.
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Tref Hodge
Chief Operations Officer, Deanan Gourmet Popcorn

The Problem

Deanan's restricted factory space imposes a significant limitation, necessitating a compact solution without requiring physical expansion. As Deanan aims to increase production, this space constraint becomes even more pressing, underscoring the need to optimize current layouts. Adding to this problem is a labor shortage due to the quality of work, given the repetitive nature of tasks like palletizing.

The Solution

To tackle this problem, Deanan Popcorn is successfully using Robotiq's PE20 Palletizing Solution. The solution is positioned at the end of two conveyors, using very little space in the existing layout. This automation is taking over repetitive tasks that previously relied on manual labor, thus improving the overall quality of work and freeing up staff to focus on more critical aspects of production. The collaborative design of the cobot enables it to work safely alongside staff without protective enclosures, improving both efficiency and safety.

Convincing wins with the Robotiq Palletizing Solution


MINIMAL IMPACT ON CURRENT LAYOUT

The PE20 utilizing only half of a pallet in size was a pivotal point for Deanan's decision to choose Robotiq cobot palletizing solution. It allowed Deanan to effectively optimize the utilization of available space.


QUICK INSTALL

We deploy automation projects using lean robotics principles, ensuring that factory production starts faster with minimal disruptions. Assisted by our partner, Olympus Controls, the installation was completed in just 3 days with the aid of our start-up assistant.


SCALABILITY

With the increasing demand from Deanan, the PE20 can sustain increasing production levels using a configuration of two conveyors linked to one palletizer. The solution can handle up to 13 cycles per minute. 

 

The Robotiq solution

The Robotiq Palletizing Solution ensures consistent palletizing, ease of use and boosts productivity.
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PE20vac
Applications

Palletizing

The Robotiq Palletizing Solution significantly transformed Deanan Popcorn's operations. By automating the monotonous palletizing tasks, the company was able to reallocate people to more strategic roles resulting in a more pleasant and engaging work environment, and making it easier to retain employees. Staff members appreciated the reduced repetitive demands and the opportunity to focus on more fulfilling responsibilities. Additionally, the adoption of the solution facilitated a quick return on investment, as the efficiency gains and reduction in labor expenses rapidly offset the initial costs. 

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