Optimizing food distribution throughput with Destuff-it™

The Challenge: Overcoming the manual unloading bottleneck

For a national food retailer, dock efficiency is the starting point for the inbound process. Distribution centers in their network faced a constant bottleneck caused by manual unloading. Two-person teams handled a mix of boxes, bags, and poly-wrapped packages. The retailer had a conventional case rate of 677 cases per hour.

This manual process required 11.1 man-hours for every trailer. The results were high labor costs and physical strain for both internal staff and third-party workers. Management wanted to lower the cost of moving goods to market. The executive team needed a solution to increase throughput without a total facility overhaul or risks to worker safety.

The Solution: The Destuff-it™ portable ergonomic conveyor

The retailer tested the Destuff-it system to address these requirements. This self-propelled conveyor connects the interior of a trailer to the facility's existing belt system. The unit was selected for its specific technical capabilities.

The operator platform has a 550 lb capacity and lifts workers 27.5 inches from the floor. This removes the need for step stools. The conveyor uses a 24-inch wide belt with a 165 lb capacity. A throttle-style handle provides control over vertical and horizontal positioning. The machine moves between different docks at 50 feet per minute using an independent DC drive.

The Execution: Precision and speed in action

The project video shows the execution phase focused on the reach zone. An operator drives the Destuff-it directly into the trailer and stands on a pressure-sensitive safety mat.

The operator uses the pivoting conveyor to create a straight path from the top of the product wall to the downstream conveyor. Workers adjust the height in real time using motorcycle-style throttle controls. They slide bags and poly-wrapped packages onto the belt. This method reduces the need for twisting or heavy lifting. The process creates a rhythmic flow. A second worker at the end of the line handles sorting and palletization. This setup reduces the time spent handling each individual item.

The Result: Industrial scale return on investment

The use of the Destuff-it changed dock performance for the retailer. Case rates moved from 677 to 1,540 per hour. This was a 127 percent improvement. Man-hours required for each trailer dropped from 11.1 to 4.8. This change was a 56 percent reduction in labor time.

The speed and the reduced reliance on outside labor led to a return on investment in under nine months. The retailer maintained its focus on safety and continuous improvement. The workforce remains productive and healthy.