The right chemistry with the client leads to winning solution

Overview
A national manufacturer which reconditions, re-certifies and refills chemical tanks, contacted Cherry’s Industrial Equipment for assistance in two critical operational areas: (1) Mitigating significant worker injuries; and (2) Improving efficiencies in re-filling tanks. The tanks measure four feet in height by ten inches in diameter; each weighs up to 110 pounds. Relying heavily upon workers to move the tanks on and off pallets, the company had reached the limit of its internal resources and sought out Cherry’s expertise. Cherry’s Industrial Equipment Account Manager Russ Catt worked with the manufacturer’s leadership, maintenance and engineering teams to evaluate the company’s needs and provide a solution.


The Challenge
The manufacturer receives shipments of empty tanks needing reconditioning (and recertifying them to be certain that the tanks meet safety standards, as some tanks have been in use for fifty years). The company fills the tanks with liquid or gas chemicals, such as helium, and ships to the end users who have placed the orders. Whether full or empty, each tank must be placed on or removed from a pallet; each pallet holds between 12 and 16 tanks. Moving tanks onto the pallets individually has been accomplished by two workers picking them up and moving them. This is extremely labor-intensive. Because of the weight of the tanks and the repetitive motions required to lift and move, the potential for worker injury is high. The shipping and unloading process is further complicated in that the tanks cannot be shipped in an upright position. They are filled right side up, moved onto pallets, and then they must be rotated for shipment in a horizontal position. Another challenge is that the manufacturer has its own specifically designed set of wooden spacers used to hold the tanks in place on the pallets, and wanted the proposed solution to accommodate its existing spacers.


The Solution
Following a series of discovery meetings with the client, the Cherry’s team recommended the implementation of a pallet tipper, which could rotate the angle of the tanks on each pallet for shipping, and also reduce the number of times workers would need to handle the heavy tanks. To accommodate the dimensions of the specific spacers used between the tanks on the pallets, Cherry’s recommended customizing the tipper with locking bars that hold the wooden spacers and tanks firmly in place, preventing any rolling around of the tanks when being transported.
 
This was a first-time engagement with this client for Cherry’s, and the customized portable tipper serves as a prototype for the manufacturer. And this tipper design may have applications beyond this specific client’s needs, as these tanks are standard size and many chemical companies face the issue of transporting them in an efficient way and one that reduces the likelihood of workplace injury.


The Results
The customized portable pallet tipper was recently placed in service at the manufacturer. In its short time in use, it has already yielded significant dividends for the client. Using the tipper has reduced the number of employees needed to move the tanks from two to one, saving 50% on labor costs and freeing the second employee to handle other tasks. It has also eliminated the need for lifting and bending, as the tanks can be rolled onto the tipper. Previously, the client did not have a way to tip the tanks and had to unstack them from the ground level. The client is thrilled with the initial performance of the customized tipper; the machine has become an integral part of its manufacturing and distribution process. As a result, the company is in discussions with Cherry’s to provide seven to ten more units for this client’s other locations.


Conclusion
The project was a collaboration of engineering, design and ideas in an atmosphere of trust and mutual respect. Building that level of trust created the right “chemistry” between Cherry’s and the client where both sides worked toward several common goals: reducing worker injury and improving time and efficiency on the manufacturing floor. The result is a machine that Cherry’s can replicate for this client in its additional locations and potentially help other companies in the same industry. Our team is very passionate when it comes to providing unique solutions. In this case our solution – customizing a piece of equipment to suit a particular client’s needs – helps us continue our mission of positively impacting the lives of everyday people.