{"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":"2026-06-19T23:09:47","modified_gmt":"2026-06-19T23:09:47","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 class=\"wp-block-paragraph\">Huhtamaki is a global manufacturer of food packaging products with demanding uptime requirements across its production and material handling operations. At its Sacramento, California facility, palletized loads must move continuously from production to storage without interruption.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">To modernize this critical flow path, Huhtamaki partnered with FloStor and Veritiv on a targeted facility upgrade focused on reliability, control, and long-term operational performance.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The Challenge<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Huhtamaki&#8217;s Sacramento operation depended on aging transfer equipment and outdated controls that introduced avoidable risk, rising maintenance cost, and unstable pallet flow. The site needed a practical modernization strategy that would improve control without forcing a full facility redesign.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Escalating Maintenance Burden:<\/strong> A 25-year-old vertical material lift required frequent repairs, creating downtime risk and unpredictable service costs in a production-critical area.<\/li>\n\n\n\n<li><strong>Inconsistent Load Control:<\/strong> Legacy conveyor and stretch-wrapping equipment lacked the control depth needed for varied pallet profiles, resulting in unstable handling and preventable quality concerns.<\/li>\n\n\n\n<li><strong>Loss of Zero-Pressure Accumulation:<\/strong> The downstairs accumulation run could no longer reliably separate pallets, increasing contact risk and disrupting continuous flow.<\/li>\n\n\n\n<li><strong>Budget Pressure on Traditional Approaches:<\/strong> Initial quotes from elevator-focused vendors exceeded project budget, requiring an integrated alternative that delivered performance without overbuilding.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">The Solution<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">FloStor engineered a staged modernization program that treated pallet transfer as one connected workflow, not a set of isolated equipment replacements. The goal was to restore predictable movement from upper-floor discharge through accumulation and vertical transfer to downstream handling.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Working alongside Huhtamaki and Veritiv, FloStor delivered a practical upgrade path that improved controls, reduced maintenance exposure, and stabilized load handling performance across the full run.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Systems Used<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>LanTech Stretch Wrapper and Upper Conveyor Upgrades:<\/strong> Replaced legacy upper-floor equipment with modern wrapping and transfer controls that automatically adapt to pallet load requirements.<\/li>\n\n\n\n<li><strong>Hytrol EZ-Logic Zero-Pressure Accumulation:<\/strong> Added zoned accumulation intelligence to keep pallets separated, protect product integrity, and maintain controlled downstream flow.<\/li>\n\n\n\n<li><strong>PFlow 4-Post Mechanical Lift with Powered Conveyor Bed:<\/strong> Replaced the aging welded lift with a modern vertical transfer system that receives and discharges pallets as a direct extension of conveyor flow.<\/li>\n\n\n\n<li><strong>Custom Controls Panel and Electrical Integration:<\/strong> Unified the new systems under a coordinated controls architecture with updated logic and safety interlocks across each stage.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\">The Power of Integration in Action<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">FloStor&#8217;s value came from orchestrating each system as part of one continuous material handling sequence. Wrapping, accumulation, and vertical transfer were engineered to communicate and hand off loads cleanly, removing the stop-and-start behavior that had previously constrained performance.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The full modernization was executed in a tight three-week implementation window, including mechanical replacement, controls updates, electrical integration, and safety improvements.<\/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 class=\"wp-block-paragraph\">Huhtamaki replaced a fragile, maintenance-heavy transfer path with an integrated, controlled system designed for dependable daily operation. The result was a measurable improvement in implementation speed and a clear shift toward safer, more predictable pallet flow.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Instead of treating lift replacement as a standalone project, FloStor delivered a complete flow modernization that improved reliability at each handoff point and reduced operational friction across the line.<\/p>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-f56f613f wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column caseStudyResultsBox is-layout-flow wp-block-column-is-layout-flow\">\n<h3 class=\"wp-block-heading\">Key Performance Gains<\/h3>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Implementation Speed:<\/strong> Full modernization delivered in 21 days from removal through integrated startup<\/li>\n\n\n\n<li><strong>Reliability Improvement:<\/strong> Replaced a 25-year-old high-maintenance lift with a modern, conveyor-integrated vertical transfer system<\/li>\n\n\n\n<li><strong>Flow Stability:<\/strong> Restored zero-pressure accumulation behavior to reduce pallet contact risk and keep downstream movement controlled<\/li>\n\n\n\n<li><strong>Load Handling Quality:<\/strong> Added control depth for varied pallet profiles, improving wrap consistency and operational confidence<\/li>\n<\/ul>\n\n<\/div>\n\n<\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Why This Worked<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">This project succeeded because Huhtamaki and FloStor focused on workflow integration, not one-for-one equipment swap decisions. The strategy addressed root causes of downtime and instability while preserving a realistic implementation path.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>End-to-End Integration:<\/strong> Wrapping, accumulation, and vertical transport were designed as one coordinated system, eliminating handoff gaps that previously created operational drag.<\/li>\n\n\n\n<li><strong>Reliability-First Engineering:<\/strong> Replacing aging failure points with modern mechanical and control systems reduced unplanned disruption and improved day-to-day predictability.<\/li>\n\n\n\n<li><strong>Control Depth for Real Loads:<\/strong> The upgraded control environment was built around load variability, improving consistency without relying on constant operator correction.<\/li>\n\n\n\n<li><strong>Execution Without Overbuild:<\/strong> FloStor delivered a budget-conscious, staged modernization that solved immediate risk while creating a stronger foundation for future upgrades.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\">Related Services<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>System Integration and Controls Engineering<\/li>\n\n\n\n<li>Conveyor and Accumulation Modernization<\/li>\n\n\n\n<li>Vertical Material Lift Upgrades<\/li>\n\n\n\n<li>Installation, Startup, and Lifecycle Support<\/li>\n<\/ul>\n\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":[22,27],"tags":[46],"class_list":["post-263","case-study","type-case-study","status-publish","has-post-thumbnail","hentry","category-intelligent-motion","category-manufacturing","tag-ergonomics"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.7 - 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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