Case Study: Beef Products Inc. achieves 20 million‑lb high‑density automated freezer storage and enhanced food‑safety/efficiency with Westfalia Tech. Inc.

Beef Products Inc. - Customer Case Study

Beef Products Inc., a major boneless lean beef manufacturer operating near Sioux City, Nebraska, faced rapid production growth—nearly 1,000,000 lbs/day—and needed freezer storage for over 20 million pounds of product while meeting strict food‑safety and quarantine requirements. To apply post‑production bar codes, quarantine pallets until lab results were available, and optimize a site located 400' from the plant, Beef Products Inc. contracted Westfalia Tech. Inc. to deliver an Automated Storage and Retrieval System (AS/RS) and Warehouse Management System (WMS).

Westfalia Tech. Inc. implemented a high‑density, multiple‑deep AS/RS with two Storage Retrieval Machines per aisle, a Satellite® rack entry vehicle, automatic palletizer/print‑and‑apply labeling, and an integrated WMS. The 15‑level system provides 11,886 pallet positions in a 20,235 sq ft freezer, 110 pallets/hour throughput, 850 ft of conveyors and four refrigerated truck‑staging lanes; the WMS automates quarantine/release, interfaces with BPI’s host, and stages orders. As a result, Beef Products Inc. gained storage for over 20 million lbs in one‑third the typical freezer footprint, reduced labor and error rates, increased order processing speed, and improved inventory and food‑safety control.

Beef Products Inc.