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MORE THAN A SUPPLIER
āNobody on the market made something that went that fast.ā
Marshall Stanelle, Pack Air
Most tote stacking systems top out around 10 to 12 cycles per minute. Pack Air was asked to build one that ran nearly twice as fast. From the beginning, it was clear this wouldn't be a standard machineāor a standard engineering decision.
Fortunately, Pack Air wasnāt tackling the challenge alone. For more than 40 years, Werner has worked alongside Pack Air as a trusted engineering partner, providing technical support, application expertise, and guidance across a wide range of automation projects.
Through regular collaboration and monthly planning meetings, Werner stays closely aligned with Pack Airās evolving needs, helping engineers identify solutions, troubleshoot challenges, and evaluate new technologies. When this unprecedented request arrived, Pack Air knew they had a partner ready to help.
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A SPEED PROBLEM THE MARKET HADNāT SOLVED
The system was designed to stack and destack empty plastic food-handling totes for a major food manufacturer. The performance requirement was simple to define but difficult to achieve: operate at speeds far beyond what existing equipment on the market could deliver.
As Pack Air explored potential solutions, one of their mechanical engineers began using Rockwell Automationās Motion Analyzer software to model the application. The analysis revealed a path forwardābut it would require a motion solution capable of delivering exceptional speed and precision.
Werner worked closely with Pack Airās engineering team to evaluate options, provide technical guidance, and connect the team with additional Rockwell Automation resources when needed. Rather than starting from scratch, the team leveraged technologies they already trusted and understood, reducing risk while pushing performance boundaries.
FROM CONCEPT TO CAPABILITY
Just over a year after receiving the order, Pack Air delivered a custom tote stacker and destacker unlike anything currently available on the market.
By combining innovative machine design, Rockwell Automation motion technology, and Wernerās technical support, the team developed a solution capable of reaching speeds of up to 22 totes per minute while maintaining reliability and control.
What began as an ambitious request became a new benchmark for high-speed tote handling performance.
WHAT MADE IT POSSIBLE
Together, these elements helped transform an unprecedented performance requirement into a reliable, production-ready solution.
LESSONS FROM A RECORD-SETTING PROJECT
For manufacturers and machine builders facing new challenges, the Pack Air team offers several key takeaways:
- Work with partners who consistently deliver reliable, high-quality products.
- Reduce risk by applying proven technologies in new ways.
- Take advantage of the combined expertise available through Werner and Rockwell Automation.
WHAT THE FINISHED MACHINE MADE POSSIBLE
The completed system enabled Pack Airās customer to stack totes at nearly double the traditional industry rate, creating meaningful gains in throughput and operational efficiency.
More importantly, the project demonstrated how proven motion technology and collaborative engineering can turn ambitious performance goals into reliable, production-ready solutions.
āOur relationship with Werner and what we rely on Werner for was very much the same on this project as it would be any other.ā
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