Everest Food Products

How Everest Food Scaled Output to 1,200 tons Daily with Daifuku Unit Load ASRS Systems

Note: This video features the original installation before its subsequent expansion. The specifications in the case study below reflect the expanded system.

Client Background

Founded in 1967, Everest Food Products Pvt. Ltd. manufactures more than 75 kinds of Everest Masala and other spice products. The company exports to over 80 countries—including the UK, Singapore, Australia, and others—as well as across India, and has received Superbrand recognition 10 consecutive times. To meet the company's daily target of producing 1,200 tons of spices at its 37,560 sqm factory, the facility maintains a raw material stock of over 1,600 tons.

Operational Challenges

Before implementing automated storage and retrieval systems (ASRS), raw materials and finished products were stored on a manual racking system at the company's old factory:

• Delayed Production Staging: Operations depended on manual handling, making raw material assignment to production lines time-consuming.
• Sanitary Control Risks: Storing raw spices and ingredients on manual racks created challenges for sanitary control and batch contamination prevention.
• Traceability Bottlenecks: Manual tracking hindered efficient inventory traceability and manufacturing data management.

The Solution: Unit Load ASRS solutions for Raw Materials and Finished Goods

To improve material flow, inventory control, and sanitary management, two Unit Load ASRS (Automated Storage and Retrieval System) installations were integrated into the new factory - one dedicated to raw materials and the second to finished goods and packaging materials:

• Raw Material Unit Load ASRS: Equipped with 2,160 pallet locations and 3 stacker cranes to support the timely supply of raw materials directly to production lines.
• Finished Goods Unit Load ASRS: Features 18,784 pallet locations and 10 stacker cranes located in an adjacent storage area.
• Integrated Pallet Handling: After packing, finished products are manually palletized and moved by forklift to the inbound conveyor. Sorting Transfer Vehicles (STVs) then transport the pallets automatically to the adjacent finished-goods ASRS.