Case Study: Kelly-Moore Paint Company achieves 76% first-year ROI and streamlined, safer palletizing with Honeywell Intelligrated

Alvey robotic palletizers from Intelligrated paint a picture of efficiency for Kelly-Moore

Kelly-Moore Paint Company, a carbon-neutral, employee-owned manufacturer based in San Carlos, CA, needed to modernize a plant that handled up to 70-pound products by hand. Tight floor space, high SKU-change rates for advanced product lines, and ergonomic/safety concerns from manual palletizing drove the company to seek a scalable material-handling partner.

Kelly‑Moore selected Intelligrated’s Alvey robotic palletizers with Motoman arms and custom end-of-arm tooling, Accuglide zero‑pressure accumulation, pallet dispensing and stretch-wrapping; the turnkey system was delivered on time and on budget. The automation eliminated heavy lifting, enabled changeovers to drop from 45 to 9 minutes (an 80% reduction), produced a 76% labor ROI in the first year, cut overtime, reduced lost‑time accidents dramatically, and even saved $25,000 by having robots handle empty pallets.

Kelly-Moore Paint Company

Keith Hussinger

Plant Manager