Case Study: King's Hawaiian doubles throughput and eliminates freezer damage with Bastian Solutions' robotic palletizing and deep‑lane AS/RS

King's Hawaiian - Customer Case Study

King's Hawaiian engaged Bastian Solutions to automate case palletizing and freezer storage at its Torrance, California bakery to increase throughput, achieve 100% order visibility, consolidate two facilities into one, and eliminate freezer damage from high fork truck activity. The project leveraged a Robotic Palletizing System and Freezer Deep Lane AS/RS, including Exacta Warehouse Management and Control Systems, case palletizing robots, conveyors, and a Woodson AS/RS.

Bastian Solutions implemented integrated robotic palletizing cells, conveyor and slip-sheet handling, robotics controls, and the Exacta WMS/WCS to manage flow and storage. As a result, the two facilities were consolidated into one, finished goods capacity nearly doubled from 6,500 lbs/hour to 12,000 lbs/hour, and freezer damage from fork truck activity was eliminated.

King's Hawaiian