Land O’Frost Boosts Efficiency and Safety with Formic Robots
In today’s competitive manufacturing landscape, companies are constantly seeking ways to optimize operations, reduce costs, and improve employee safety. For Land O’Frost, a leading U.S. meat producer based in Lansing, Illinois, the answer came in the form of automation through Formic, a Robots-as-a-Service (RaaS) provider. By deploying five gantry-style palletizing robots at their facility, Land O’Frost achieved a 20% reduction in daily labor-related operational expenses while simultaneously upskilling its workforce. This transformation not only streamlined production but also enhanced workplace safety and efficiency.
The Challenge: Balancing Productivity and Employee Well-Being
Land O’Frost produces over 128,000 pounds of meat daily, managing multiple stock-keeping units (SKUs) that require frequent changeovers. Each changeover involved retraining employees on new pallet patterns—a time-consuming process that diverted valuable resources away from productivity-enhancing tasks. Additionally, manual palletizing exposed workers to repetitive strain injuries and other physical risks, creating a pressing need for safer, more efficient solutions.
Frank Mejia, Continuous Improvement Supervisor at Land O’Frost, recognized the potential of automation to address these challenges. “When I saw the opportunity for automation to eliminate repetitive production line tasks while simultaneously improving our employees’ lives, it was an easy decision,” he said. With this vision in mind, Land O’Frost partnered with Formic to implement robotic systems designed to revolutionize their end-of-line production processes.
The Solution: Formic’s Full Service Palletizer Rental Program
Formic’s approach to automation is rooted in simplicity and flexibility. Their Full Service Palletizer Rental program offers manufacturers access to cutting-edge robotic technology without the hefty upfront investment typically associated with automation. For Land O’Frost, this meant deploying five gantry-style palletizing robots tailored to meet the specific needs of their operation.
The deployment process was seamless, taking place over two weekends without disrupting ongoing production. During this period, Formic programmed pallet patterns for all SKUs and trained floor operators to manage the new robotic systems. Employees who once manually stacked boxes onto pallets transitioned into roles as robot operators, gaining valuable technical skills in the process.
One of the standout features of Formic’s solution is its ability to simplify changeovers. What used to involve lengthy discussions between team members can now be accomplished with just a few clicks on a touchscreen interface. This dramatic improvement has eliminated unnecessary downtime and allowed employees to focus on higher-value activities that contribute directly to business growth.
Tangible Results: Cost Savings and Workforce Upskilling
Since implementing Formic’s robotic systems, Land O’Frost has realized significant benefits:
- Reduced Labor Costs: The company saves 20% on labor-related operational expenses every day. These savings stem from reduced reliance on manual labor for repetitive tasks, freeing up human capital for more strategic initiatives.
- Improved Safety: Automation has minimized the risk of workplace injuries by removing employees from physically demanding and repetitive tasks. This shift aligns with Land O’Frost’s commitment to prioritizing worker well-being.
- Increased Efficiency: Changeovers are faster and more accurate, enabling smoother transitions between different SKUs. This has led to increased throughput and greater overall productivity.
- Workforce Development: Employees have been upskilled to operate advanced robotic systems, enhancing their career prospects and job satisfaction. This investment in human capital ensures that Land O’Frost remains competitive in attracting top talent.
Saman Farid, Founder and CEO of Formic, emphasized the transformative impact of automation on Land O’Frost’s operations. “By adding our palletizing solutions to their production line, they’ve eliminated unnecessary downtime, upskilled employees to robot operators, and reduced overall OpEx spend,” he said. “Automation was the final missing piece in driving their production efficiency even further.”
A Comprehensive Support System
What sets Formic apart is its commitment to providing end-to-end support throughout the lifecycle of its robotic deployments. Through the Full Service Palletizer Rental program, Land O’Frost gains access to four fully supported turnkey palletizing solutions for a fixed monthly or annual rate. Key components of the program include:
- 24/7 Technical Support: Ensuring minimal disruptions to production.
- Preventative and Corrective Maintenance Coverage: Addressing issues before they escalate.
- Contracted Performance Rates: Guaranteeing consistent output levels.
- Equipment Swapping: Allowing for quick replacements if needed.
- Short Lead Times: Delivering equipment within 10 weeks or less.
This comprehensive package gives manufacturers peace of mind, knowing that their automation investments are backed by reliable support and maintenance services.
Showcasing Success: An Open House Event
To celebrate the successful integration of Formic’s robotic systems, Land O’Frost will host a Formic Automation Community event at their Illinois facility on April 30th. Attendees will have the opportunity to see firsthand how these innovative solutions are supporting the production of 128,000 pounds of meat daily. The event will highlight the tangible benefits of automation, including cost savings, improved safety, and workforce development.
Looking Ahead: The Future of Manufacturing
Land O’Frost’s partnership with Formic exemplifies the power of automation to drive meaningful change in the manufacturing sector. By embracing robotic technology, the company has not only optimized its operations but also set a benchmark for others in the industry. As automation continues to evolve, forward-thinking organizations like Land O’Frost will remain at the forefront, leveraging innovation to achieve sustainable growth.
For manufacturers considering automation, the message is clear: investing in robotics isn’t just about cutting costs—it’s about empowering your workforce, enhancing safety, and building a foundation for long-term success. With partners like Formic leading the way, the future of manufacturing looks brighter than ever.
