Solutions

food

A line for sorting frozen foods by store. Standard conveyors produce great results.

Muroo Co., Ltd. Matsuyama Branch Freezing Center

A line for sorting frozen foods by store. Standard conveyors produce great results.

overview

A simple automated sorting line consisting of Unicon V and free roller conveyors was introduced to the freezing center of the Matsuyama branch (Matsuyama City, Ehime Prefecture), which serves as the base for the Shikoku area. By automating the previous manual sorting, work time was shortened and the burden on workers was significantly reduced.

overview

Background to the introduction of the equipment

The freezing center handles approximately 500 types of frozen foods and ice cream, sorting and shipping approximately 5,000 cases per day to each store (68 stores). Until now, the center had been sorting products by store using a manual process, as shown in the diagram below. This posed many issues, including the burden on workers, the time it took, and the likelihood of errors. To address these issues, a conveyor system was installed to automate the sorting process.

[Conventional shipping sorting work]

① Attach shipping label to product case

① Attach shipping label to product case

②Transporting product cases on a cart

②Transporting product cases on a cart

③ Load the products into the cart

③ Load the products into the cart

Effects of introducing equipment

The conveyor equipment introduced is a simple sorting facility consisting of a Unicon V drive line, a high-speed transfer machine with a sorting capacity of 1,500 items per hour, and three free roller conveyors for storing the sorted items. Shipping labels are automatically affixed to product cases on the conveyor line, and a barcode reader determines the destination lane. The high-speed transfer machine then sorts the products into the appropriate lane, where they are stored on the three free roller conveyors.

Scanning the barcode on the case at the conveyor entry point

Scanning the barcode on the case at the conveyor entry point

Three high-speed transfer machines sort by destination

Three high-speed transfer machines sort by destination

Loading into refrigerated basket trucks for each store

Loading into refrigerated basket trucks for each store

Each storage lane has basket carts for around 20 stores on either side. Two workers are assigned to each lane, and they load products into the appropriate basket cart while checking the shipping labels on the cases on the conveyor. Although there is still the task of searching for basket carts, the number of stores each worker receives is low at around 10, so loading can proceed quickly. There is also no longer any need to attach shipping labels or transport carts to the basket carts, which has also reduced the number of workers required. Furthermore, the system has resolved many of the issues that existed during the manual sorting era, such as improved shipping accuracy due to a reduction in sorting errors and stronger product temperature control.

Customer testimonials

Working in a refrigerated environment is tough, and we needed young, physically fit personnel, but recruitment was difficult and retention rates were low. We had been considering automation from the start of operations, but this was delayed. By introducing the sorting equipment this time, we have been able to reduce the amount of human intervention and shorten work hours, which has greatly improved productivity. In addition, the work has become easier, and it is now possible to hire employees regardless of age or gender, which is a major factor.

Company Name
Muroo Co., Ltd.
Business content
Automobile transport business / Special combined transport work / Type 1 transport business / Light cargo vehicle transport business / Warehousing business / Food sorting and delivery agency business
Number of employees
6,270 people
Customer testimonials
*The content of this article is based on interviews conducted in October 2020. The numerical data and organizational information in the article are current as of the time of the interviews.