Case Study: Kelly-Moore Paint Company achieves 76% first-year ROI and greater efficiency with Honeywell Alvey robotic palletizers

Alvey Robotic Palletizers From Honeywell Intelligrated Paint a Picture of Efficiency for Kelly-Moore

Kelly-Moore Paint Company, a large employee-owned paint manufacturer, faced safety, ergonomic and throughput challenges at its San Carlos plant from manual palletizing of heavy cans and pails and frequent SKU changeovers. Seeking a turnkey integrator, Kelly-Moore selected Honeywell Intelligrated (Honeywell) to modernize its end-of-line with a compact, flexible solution that would fit existing building constraints and support smaller, higher-mix production runs.

Honeywell delivered an Alvey robotic palletizing system with Motoman arms, Accuglide zero-pressure accumulation conveyors, custom end-of-arm tooling, pallet handling and integrated controls, plus a stretch wrapper and pallet dispenser. The solution enabled quick pattern additions, avoided structural modifications and even saved $25,000 by having robots place empty pallets. Results included a 76% labor ROI in the first year, an 80% reduction in changeover time (45 to 9 minutes), sharply reduced overtime and a drop in lost-time accidents (from 23 to 5), all delivered on time and on budget by Honeywell.

Kelly-Moore Paint Company

Keith Hussinger

Plant Manager