{"id":263,"date":"2026-03-18T19:37:09","date_gmt":"2026-03-18T19:37:09","guid":{"rendered":"https:\/\/api.flostor.com\/backend\/?post_type=case-study&#038;p=263"},"modified":"2026-03-18T19:37:10","modified_gmt":"2026-03-18T19:37:10","slug":"elevating-huhtamaki-how-flostor-built-a-high-performance-vertical-flow-in-21-days","status":"publish","type":"case-study","link":"https:\/\/api.flostor.com\/backend\/case-study\/elevating-huhtamaki-how-flostor-built-a-high-performance-vertical-flow-in-21-days\/","title":{"rendered":"Elevating Huhtamaki: How FloStor Built a High-Performance Vertical Flow in 21 Days"},"content":{"rendered":"\n<h1 class=\"wp-block-heading\">From Maintenance Headaches to Seamless Elevation: How Intelligent Modernization Built Predictable Performance for Huhtamaki<\/h1>\n\n\n\n<h2 class=\"wp-block-heading\">The Client: Huhtamaki<\/h2>\n\n\n\n<p>Huhtamaki is an international manufacturer specializing in high-quality food packaging materials. At their Sacramento, California facility, they manage the critical transfer of palletized products from manufacturing stages to final storage.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The Challenge<\/h2>\n\n\n\n<p>As a global leader in packaging, Huhtamaki requires absolute reliability in its material handling to maintain production flow. However, their Sacramento facility was hindered by an aging infrastructure that could no longer keep pace with modern operational demands. Their existing methods, while functional in the past, became a source of significant risk and escalating costs.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">The Bottlenecks of Manual Processes<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Constant Maintenance Demands:<\/strong> The centerpiece of their pallet transfer process\u2014a 25-year-old vertical material lift\u2014had become a massive liability. The unit required near-constant repair, leading to unpredictable downtime and high maintenance expenses.<\/li>\n\n\n\n<li><strong>Inconsistent Load Handling:<\/strong> The existing plastic stretch wrapper and outdated conveyor sections lacked the precision necessary for modern standards. Because different pallet loads required specific wraps and tensions, the old system\u2019s lack of depth in controls created quality and stability issues.<\/li>\n\n\n\n<li><strong>Loss of Flow Control:<\/strong> The downstairs accumulation conveyor had lost its ability to effectively separate loads at the end of the run. This resulted in a loss of &#8220;zero-pressure&#8221; functionality, leading to potential product damage and disrupted workflow momentum.<\/li>\n\n\n\n<li><strong>Budgetary Constraints:<\/strong> Initial inquiries into traditional elevator companies yielded proposals that far exceeded the facility&#8217;s project budget, requiring a more innovative and cost-effective engineering approach.<br><\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">The Solution<\/h2>\n\n\n\n<p>Recognizing that their operational performance needed to match their manufacturing excellence, Huhtamaki sought a fundamental shift in their facility\u2019s logistics. They didn\u2019t just need a replacement lift; they needed a complete, integrated system designed to bring order and intelligence to their pallet handling.<\/p>\n\n\n\n<p>FloStor partnered with Huhtamaki and Veritiv to engineer a multi-stage solution that transformed their facility into a predictable, efficient powerhouse.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Engineering the Flow: A Three-Stage Modernization<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Precision Wrapping and Control:<\/strong> FloStor replaced the upper-floor conveyor and stretch wrapper with a state-of-the-art LanTech unit. This system introduced the &#8220;depth of controls&#8221; Huhtamaki required, allowing for automated adjustments to wrap tension based on specific pallet load requirements.<\/li>\n\n\n\n<li><strong>Intelligent Accumulation:<\/strong> To restore order to the downstairs flow, FloStor implemented Hytrol EZ-Logic Zero-Pressure accumulation conveyors. This system uses zoned intelligence to automatically manage the movement and stopping of pallets, ensuring they remain separated and protected without the need for manual intervention.<\/li>\n\n\n\n<li><strong>Advanced Vertical Integration:<\/strong> The most complex phase involved the surgical removal of the original 25HP welded lift structure. In its place, FloStor installed a PFlow Mechanical 4-post lift, specifically modified with a powered conveyor bed. This integration allows the lift to act as a seamless extension of the conveyor line, automatically receiving and discharging pallets.<\/li>\n<\/ul>\n\n\n\n<p><strong>The Power of Integration in Action<\/strong> FloStor\u2019s role as the integrator was critical in executing this overhaul within a tight three-week window. They didn\u2019t just install pieces; they created a unified workflow engine. The project included a comprehensive electrical setup, a custom control panel, and an upgraded controls program that brought modern safety systems to every stage of the process.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"967\" height=\"640\" src=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2026\/03\/huhtamaki_001_003.jpg\" alt=\"Huhtamaki Modernization Details\" class=\"wp-image-265\" srcset=\"https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2026\/03\/huhtamaki_001_003.jpg 967w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2026\/03\/huhtamaki_001_003-300x199.jpg 300w, https:\/\/api.flostor.com\/backend\/wp-content\/uploads\/2026\/03\/huhtamaki_001_003-768x508.jpg 768w\" sizes=\"auto, (max-width: 967px) 100vw, 967px\" \/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">The Results<\/h2>\n\n\n\n<p>The flexibility and control offered by the new mechanical lift and intelligent accumulation conveyors eliminated the maintenance guesswork of the past. Huhtamaki\u2019s Sacramento facility now operates with a system that is both more reliable and more capable of handling diverse product loads with precision.<\/p>\n\n\n\n<p>The transition from an aging, high-maintenance lift to a fully integrated vertical solution was completed in just 21 days from start to finish. By partnering with an experienced system integrator like FloStor, Huhtamaki transformed a potential bottleneck into a predictable and intelligent material handling system, ensuring their operational flow is as high-performing as the packaging products they produce.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>FloStor Modernizes Huhtamaki\u2019s Sacramento Facility Discover how FloStor replaced a failing 25-year-old lift with an intelligent, multi-stage vertical solution in just three weeks. This strategic upgrade eliminated constant maintenance downtime and restored peak operational flow.<\/p>\n","protected":false},"featured_media":264,"template":"","meta":{"_acf_changed":false},"categories":[],"tags":[],"class_list":["post-263","case-study","type-case-study","status-publish","has-post-thumbnail","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.5 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Elevating Huhtamaki: How FloStor Built a High-Performance Vertical Flow in 21 Days - Flostor<\/title>\n<meta name=\"robots\" content=\"noindex, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Elevating Huhtamaki: How FloStor Built a High-Performance Vertical Flow in 21 Days - Flostor\" \/>\n<meta property=\"og:description\" content=\"FloStor Modernizes Huhtamaki\u2019s Sacramento Facility Discover how FloStor replaced a failing 25-year-old lift with an intelligent, multi-stage vertical solution in just three weeks. 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