Case Study: Hussmann achieves 100 cases in 9 hours and reduces operators from 110 to 75 with Bastian Solutions

Hussmann - Customer Case Study

Hussmann, a global leader in refrigerated food display solutions, engaged Bastian Solutions to replace a single food display cooler assembly line with three sub‑assembly lines converging onto a paced main line. Management wanted a constantly moving, automated line with improved ergonomics, while Bastian Solutions had to accommodate large, flimsy components across a 1.5 million sq. ft. facility and a wide variety of product sizes and weights. Key technologies included Hytrol conveyors, Bastian Automation Engineering equipment (base tipper, canopy flipper, dolly transfer, canopy gantry), Allen‑Bradley PLC with Parker CTC HMI, Zimmerman bridge cranes, and ergonomic operator manipulators.

Bastian Solutions implemented the three sub‑assembly lines and integrated automation and ergonomic handling systems to maintain continuous, paced flow. The solution increased throughput to 100 display cases in 9 hours (up from 100 in 10 hours) and reduced required assembly operators from 110 to 75, demonstrating clear productivity and labor‑efficiency gains.

Hussmann