Case Study: Blue Bell Creameries achieves 115% more freezer storage and up to 200 pallets/hr throughput with Westfalia Tech. Inc.'s AS/RS and Savanna.NET WMS

Blue Bell Creameries improves operations to keep up with growth

Blue Bell Creameries in Sylacauga, Alabama — a long-established ice cream producer — was running out of pallet storage and needed to streamline operations to keep up with growth. To solve this, Blue Bell partnered with Westfalia Tech. Inc. and installed a Westfalia Automated Storage and Retrieval System (AS/RS), Savanna.NET® Warehouse Management System (WMS) and a 400‑ft conveying system in its -30°F deep‑freeze facility.

Westfalia Tech. Inc.’s implementation— a 9‑level AS/RS with two Storage/Retrieval Machines, Satellite® multiple‑deep racking and Savanna.NET® modules for order picking, order management and warehouse balancing—raised capacity from ~3,000 to over 7,000 pallet positions (about a 115% increase), delivered up to 200 pallets/hour throughput, cut forklift traffic by ~80%, reduced product damage and consolidated storage into 14,000 sq. ft., producing significant labor, flow and waste savings for Blue Bell.

Blue Bell Creameries

Kevin Wood

General Manager