Case Study: The Hershey Company achieves flexible, space‑saving hybrid palletizing automation and increased throughput with Honeywell

Hybrid Palletizing Solution Hits Sweet Spot for Hershey

The Hershey Company needed a more flexible, higher‑throughput palletizing solution at a plant that handles a wide, frequently changing mix of SKUs (Hershey’s®, Kit Kat®, Cadbury®) within a tight ~7,000 sq ft palletizing area. After years of hand‑palletizing (12–15 people per shift), rising labor costs, slow rates and ergonomic/safety concerns, Hershey engaged Honeywell Intelligrated (Honeywell) to evaluate Alvey palletizing and robotic options.

Honeywell Intelligrated delivered a hybrid system using an Alvey 780 case palletizer for mid/high‑velocity SKUs and three Motoman EPL 160 robots with UniGripper tooling for low‑velocity SKUs, plus Accuglide conveyors, a laser‑positioned transfer car, PLC controls, pattern‑generation software and on‑site training for 30+ employees. The Honeywell solution boosted throughput (Alvey 780 up to 37 cartons/min; robotic lanes handling up to 25 cpm), reduced dependence on manual palletizers and related labor/costs and ergonomic risk, was installed and commissioned in about five weeks, and has operated reliably with no major issues.

The Hershey Company

Alex Diaz

Packaging Systems Engineer