Case Studies & Testimonials - Warehouse Solutions

The Challenge: Inefficiencies due to manual unloading methods

Frogg Toggs, a retail store offering outdoor clothing and gear, faced inefficiencies in container unloading due to manual methods. Their full‑spectrum distribution center supports both big‑box retail and direct‑to‑consumer fulfillment. With no associates dedicated solely to container unloading, speed and efficiency are critical—every minute saved gets employees back to their primary roles.

Key challenges:
• Manual unloading using ladders and gravity roller conveyors was slow and inefficient
• Containers required 2–3 hours to unload manually, receiving 1-2 trailers per day
• Container unloading pulls 8-9 associates away from other warehouse priorities

The Solution: Destuff-it™ portable ergonomic conveyor system

The operation implemented the Destuff‑it™ container unloading system, to service four receiving doors. The unit is mobile, allowing it to service all four dock doors.

Key advantages:
• Faster unload times with fewer people
• Flexible deployment across multiple docks
• Proven long‑term ROI and reliability

The Execution: Accelerating unloading without increasing labor demands

One associate operates Destuff‑it ™ inside the container while five to six team members unload along the conveyor line, depending on product mix. The system dramatically accelerates unloading without increasing labor demands.

First evaluated at ProMat and deployed in 2018, Destuff‑it ™ has delivered consistent performance for more than seven years at Frogg Toggs. During a recent facility expansion, the operation reevaluated the market and—after reviewing all alternatives—selected Destuff‑it ™ again, adding a second unit for the new warehouse.

Associates consistently report that the system is safer, easier to use, and more efficient than traditional unloading methods.

The Result: The standard for container unloading

• Unload times cut by up to 50-75% (down to 1–1.5 hours per container)
• Two fewer associates required compared to manual unloading
• Faster return of employees to primary job responsibilities
• High associate satisfaction driven by safety and ease of use
• A clear winner based on performance, cost of ownership, and scalability

Destuff‑it™ continues to be the operation’s standard for container unloading—supporting efficiency today while scaling easily for future growth.

Background

Averitt is an award-winning freight transportation and supply chain services provider, specializing in LTL, dry van, international and logistics solutions. For the better part of two decades, they have been transloading containers for import and export. The company culture talks about many things, but one of the main things is how to make life better for our associates. 

The Problem

The company can receive anywhere from 2,000 to 3,000 containers per year that need to be transloaded. The process is very labor-intensive, especially when containers are floor-loaded to maximize space. It is also a manual process, leading to safety and injury issues. The physically demanding nature of the job and long hours has negatively impacted employees morale and the company has experienced higher turnover rates. 

These challenges prompted Averitt to seek a solution that would improve safety, efficiency, and the employee experience.

The Solution

Ed Smith, VP Distribution & Fulfillment, went to the executive team in corporate and said, "If we want to make the lives better of our associates, we want to build speed and efficiency, and we want to give something to our customers something to understand what we're doing, to protect their product, to make it easier to transload it: This is the machine."

Initially, employees were skeptical fearing job elimination. Employees were assured that the machines were for assistance in making the task easier and not to replace jobs. 

"The truth is, this used to be a 12-hour process for us. We'd start about six in the morning, and we'd finish up about six at night. Now we start at four in the morning and we're done by noon. From a business aspect, we're more productive. We've doubled the amount of cartons we can move per hour. Our doors are able to be utilized more times. We don't need as many doors to get the same amount done," said Kevin Flenniken, Service Center Director.

"I can't speak enough about it from an overall standpoint of how pleased I am with it. I've been doing this for over 20 years, and it's the best device we've found so far to enhance the lives of our associates, the experience for our customers, and to overall better manipulate the volumes that come in," said Ed Smith.

Background

In the supply chain industry, a “last mile” business is one that handles the final stages of product transport. One long-standing delivery company noticed how much e-commerce and internet sales were changing their last mile jobs, especially the types of products retail customers were ordering.

The Problem

Many of these products were floor-loaded and unpalletized, which required employees to manually handle every box and package. Oftentimes, moving one box would cause others to fall. It was a hazardous and inefficient process. Management and employees wanted a better way to handle unpalletized products, but some worried that pursuing new technology might displace workers.

The Solution

When their Distribution Center General Manager discovered the Destuff-it™ Portable Ergonomic Conveyor, he knew it was the right balance of technology and manpower. A single Destuff-it™ machine was purchased, a training program was developed, and reports were created that would track the new machine’s impact.

Before the Destuff-it™ was implemented, it took three employees about two and a half hours to unload a truck of unpalletized products. With the Destuff-it™ machine, two employees could do the work in an hour and a half. Employees were thrilled with how easy the machine was to operate, while management was impressed by the efficiency. Within six months, the Destuff-it™ paid itself off and another was ordered.