Projects

Optimising carton flow for packhouse record-breaking seasons at DMS Progrowers

Dyno Conveyors collaborated with DMS Progrowers to improve their carton handling, transforming manual processes into automated, on-demand systems that supported a record-breaking kiwifruit and avocado season.

THE CHALLENGE

Addressing inefficient manual handling of cartons and preparing for a major site expansion

DMS Progrowers, a leading New Zealand kiwifruit and avocado packer, experienced an unprecedented season, handling over 18.5 million trays of Class 1 kiwifruit across their two Bay of Plenty sites in Te Puna and Te Puke. To manage this record volume efficiently, DMS Progrowers initially approached Dyno Conveyors with a critical challenge at their Te Puna facility: the inefficient manual handling of empty cartons. Previously, erected boxes were stacked onto pallets and then manually moved short distances to the packing lines, a process that consumed extra labour and was highly inefficient. Laurie Jarrett, DMS Operations Manager, explained, “Previously, we were stacking our empty boxes onto pallets and moving them 5 to 10 metres. And that obviously used extra resource and was highly inefficient.“

This issue was compounded by a tight deadline, as the request was made in October for a season starting the following March, allowing minimal time for design and implementation. Subsequently, DMS Progrowers embarked on a major “greenfield” expansion at their Te Puke site, constructing one of the largest sheds in the industry. This expansion required a sophisticated carton delivery system with built-in contingency, as their tray-making machines experience intermittent downtime for refilling. The solution needed to be fit for purpose and integrated with existing machinery.

The Solution

Designing an integrated, on-demand carton delivery system with built-in contingency

Dyno Conveyors responded swiftly to DMS Progrowers’ urgent needs. Scott from Dyno conducted on-site visits, working closely with Laurie to explore various options and provide a firm commitment to delivery within the tight timeframe. “Scott was great to work to work with through this period, very proactive. We discussed multiple options. Scott gave us the great commitment that he could definitely put in place this packaging line and they delivered. That’s crucial for us, we needed to hit the ground running in March.”

For the Te Puna site, Dyno implemented a system to automate the transfer of erected cartons directly from the erectors to the packing lines, eliminating manual stacking and moving. At the Te Puke site, Dyno designed a comprehensive solution that accommodated the new, larger footprint and incorporated essential contingency. This system features a combination of belt conveyor systems to actively drive boxes to specific areas and gravity roller conveyors for cost-effective, passive movement where appropriate.

A crucial innovation was the integration of Dyno’s system with DMS Progrowers’ existing tray-making machines. Custom software was developed to enable communication between the systems, allowing for “on-demand” carton delivery. As boxes are taken from the packing line, the Dyno system signals the carton erectors to produce more, ensuring a continuous and efficient supply without over-accumulation. This sophisticated integration demonstrates Dyno’s capability in providing integrated control systems for seamless automation.

The Result

Achieving significant efficiency gains, operational reliability, and a strong, ongoing partnership

The Dyno solutions delivered immediate benefits to DMS Progrowers. The automated carton delivery systems at both sites (Te Puna and Te Puke) significantly reduced manual handling and eliminated inefficiencies, contributing to make their record-breaking season a success.

The integrated “on-demand” system at Te Puke site ensures a consistent supply of cartons while minimising waste and congestion. The use of gravity rollers also provided a cost-effective element to the overall design.

Laurie Jarrett commended Dyno’s professionalism and proactive support: “From concept to design, to build, Dyno delivered really well. The concept was simple but it was effective… They worked collaboratively with our other suppliers.” He further highlighted Dyno’s ongoing commitment, noting regular check-ins to ensure optimal operation and address any potential issues. “We appreciate that support from the initial design, the can-do attitude in terms of the short time turnaround in Te Puna, to again helping us through design and concept set up to Te Puke site, credit to Dyno, credit to Scott. It’s been a great company, great collaboration. We appreciate their help and support.“

Here’s what’s changed:

  • Manual handling reduced and inefficiencies eliminated.

  • A major site expansion with a large-scale, automated packing solution.

  • A cost-effective design using a combination of powered and gravity roller conveyors.

  • On-demand carton delivery through a system that communicates with existing machinery/equipment.

  • Operational reliability achieved with a consistent and uninterrupted supply of cartons.

Customer Testimonial

A simple yet efficient concept

From concept to design, to build, Dyno delivered really well. The concept was simple but it was effective and as a business, as an industry, that’s what we need. We appreciate their support and their can-do attitude.

Laurie Jarrett

DMS Progrowers

Products

Dyno products used in this project