Alphabetical Listing of Our Case Studies

AAP St. Mary's

AAP St. Mary's was founded in 1988. A division of Hitachi Metals, Ltd., they are a supplier for Honda, Ford, Subaru, Nissan, and Toyota. AAP produces wheels from 15" to 22" in diameter.

Accurate Dispersions - South Holland, IL

Accurate Dispersions produces the highest-quality custom colorants for the industrial marketplace. Today it is a major supplier of colorants for coatings used in the coil, aerospace, maintenance, light industrial, automotive, transportation, trade sales paint, and packaging markets.

ACH Milan

ACH Milan is a holding company created by Ford Motor Company. It was created to run several plants that supplied parts to Ford's Assembly plants. The Milan facility in Michigan continues to receive orders for new production lines to manufacture fuel tanks and bumper fascias.

Aeroquip

Aeroquip Corporation, a major manufacturer of hose and fittings, recently consolidated thirteen U.S. distribution centers down to only two. To accommodate the increased order volume, a new highly automated facility was built in Van Wert, Ohio.

Asian Paints Ltd. - Rohtak, Haryana India

Asian Paints has set up its sixth largest decorative paint plant at Rohtak, Haryana. This state of the art paint plant is located at Industrial Model Town developed by Haryana State Infrastructure and Industrial Development Corporation. With a production capacity of 400 million liters of paint every year this plant is one of the largest in the world.

Astra-CFX

Astra-CFX was tasked to design and implement a facility that would provide tires and wheels Just in Sequence (JIS) to BMW to support the carmaker’s production of the X3 SAV. The automated system was installed in a facility located in Greer, SC, in close proximity to BMW’s assembly plant.

AT&T

AT&T is the largest communications holding company in the world. They are the leading worldwide service provider of wireless high speed internet access, local and long distance voice, and directory publishing and advertising services.

Aventis

Sanofi-Aventis is one of the world’s largest pharmaceutical companies. The new distribution center located in Scranton, PA meets all eastern US demands for their vaccination products. The company is developing leading positions in seven major therapeutic areas: cardiovascular disease, thrombosis, oncology, diabetes, central nervous system, internal medicine, and vaccines.

Becton Dickinson

BD (Becton, Dickinson and Company) is a global medical technology company that is focused on improving drug therapy, enhancing the diagnosis of infectious diseases and advancing drug discovery. BD manufactures and sells medical supplies, devices, laboratory instruments, antibodies, reagents and diagnostic products through its three segments: BD Medical, BD Diagnostics and BD Biosciences. It serves healthcare institutions, life science researchers, clinical laboratories, industry and the general public.

Berry Plastics (formerly Kerr Plastics)

Berry Plastics manufactures and distributes prescription vials for several drugstore chains and superstores. Bastian Material Handling helps Berry to singulate the vials as they come out of the injection molding machines. The vials are then counted into routed cartons and ultimately automatically checked for quality, sealed, and labeled for shipment. The system interfaces with J.D. Edwards 'ERP' and has saved a tremendous amount of labor from the previous manual process.

B&H Photo

B&H Photo is a leading provider of new and used imaging products including cameras, video equipment, computers and more. More than 170,000 items are available for shipment every day from B&H Photo's Manhattan facility.

Cabela's

Cabela’s has great products for people who enjoy an outdoor lifestyle by delivering innovation, quality, and value. Started in 1961, the company has become the largest mail-order, retail, and internet outdoor outfitter in the world. With major distribution centers in Nebraska and Wisconsin, Cabela’s turned to Bastian Material Handling to help them automate a brand new distribution center in Wheeling, West Virginia.

Cambium Learning

Founded in 2003 and based in Natick, Massachusetts, Cambium Learning is an education company that provides research-based, culturally responsive and proven instructional materials, services and technology to help educators raise the achievement level of those pre K through grade 12 students under served by existing instructional materials. After selecting Longmont, Colorado as the location for their consolidated global distribution center, Cambium Learning turned to Bastian Material Handling to help them automate this new facility.

Central Power Systems

Central Power Systems distributes small engine service parts and outdoor power equipment through a network of 6000 registered service dealers in several states throughout the United States and the Bahamas.

C&H Sugar

C&H Sugar produces cane sugar and molasses for the vast U.S. market. The Crockett, CA refinery processes over 700,000 tons of pure cane sugar annually – more than 70 types, grades and package sizes, including packaged consumer sugars as well as packaged, liquid, and bulk granulated, industrial-use cane sugars.

Chelsea Milling

The Chelsea Milling Company is operated by a family whose roots in the flour milling business date back to the early 1800’s, and their private business has been milling flour in Chelsea, Michigan for over 120 years.

Citi Trends

Citi Trends Fashion for Less is a value priced family apparel retailer with over 200 stores in the southeast, mid-Atlantic region and Texas. Citi Trends success as a value retailer has resulted in the need for an expanded distribution network to include the new DC located in Darlington, SC.

Conair

Conair is a leading manufacturer and distributor of health and beauty products, and kitchen and electronic appliances. Recent acquisitions and business growth required implementation of automation to speed order processing at the East Windsor NJ distribution center.

Covance

Covance provides “value-added” design, distribution, operations and analysis for medical diagnostic testing. At the company’s distribution centers, kits are assembled with appropriate vials and related medical diagnostic devices and shipped out to customers. Where what once existed was a predominantly manual system, utilizing relatively unsophisticated material handling technologies. Bastian Material Handling has created a state of the art, automated solution.

Crown Cork & Seal

Crown Holdings, Inc., is a leading supplier of aerosol packaging, food and beverage packaging, metal closures, and specialty packaging products for consumer marketing companies around the world.

CVS.com

CVS is a leading drug store chain and retailer of consumer and medical products manufactured by nationally known suppliers as well as private labelers.

Doctors Foster & Smith

Doctors Foster and Smith is a leading provider of a wide variety of animal supplies and pet products for most all companion animals. DFS conducts its sales via phone and web orders, shipping from their distribution center in Rhinelander, Wisconsin.

Epson

Epson is a global technology company at the forefront of technological revolutions in imaging, robotics, precision machinery, and electronics. Epson offers an extensive array of award-winning image capture and image output products for the consumer, photographic, business and graphic arts markets.

Fresenius

Fresenius Medical Care is a leading manufacturer and distributor of a wide variety of dialysis products. A global leader, Fresenius provides the highest quality standards in the industry.

GameStop

GameStop, headquartered in Grapevine, TX, is a distributor and retailer of video game software, hardware and accessories. GameStop has an approximate 35-40% market share of video games and accessories.

Gardner

Gardner, Inc., a parts distributor for the lawn and garden industry, reduced dock-to-stock time by 50% with the Exacta warehouse management system and RF mobile devices.

Garmin

Garmin's goal is to create navigation and communication devices that can enright their customer's lives. Innovative products span various areas of interest, including automotive, aviation, marine, fitness, outdoor recreation and wireless applications.

Graphic Packaging Material Handling Case Study

Graphic Packaging International

Graphic Packaging International is the leading provider of paperboard packaging solutions, including folding cartons and specialty bag packaging. The company serves a widely-recognized customer base from Kellogg’s and Betty Crocker to Kimberly-Clark and MillerCoors. Bastian was tasked with designing and implementing a unique palletizing solution that optimized the company's manual palletizing process.

Greenlee

Started in 1862, Greenlee is known for it's high quality tools used in the electrical construction trade including all types of hand tools, hole making tools, cable pullers, wire terminators, and testing and measurement equipment.

Houston-Johnson, Inc.

Houston-Johnson, Inc. (HJI) provides logistic services to the largest automotive manufacturers and parts suppliers as a Tier 1 or Tier 2 supplier. The company was looking to ensure timely and accurate delivery, while also increasing throughput. Exacta helped HJI achieve its goals.

Hussmann

Since 1906, Hussmann has been inspiring solutions by helping retailers preserve and display fresh foods. Hussmann serves a wide variety of customers involved in the global cold chain. These include supermarkets, mass merchants, warehouse clubs, convenience stores, drug stores, and food service establishments.

International Paper

International Paper is the largest North American converter of paperboard for beverage packaging and a major supplier of beverage packing equipment. International Paper continues to lead the industry in innovative and proprietary developments.

Japanese Food Corporation

For over a century, JFC International has thrived in its role as a distributor, bringing an ever-expanding line of quality Japanese food products to the United States.

Johnson Controls

Since its start in 1885, Johnson Controls has grown into a global leader in automotive, building efficiency and power solutions. Johnson Controls provides batteries for automobiles and hybrid electric vehicles, along with systems engineering and service expertise.

King's Hawaiian

King’s Hawaiian Bakery, located in Torrance, California, is a producer of specialty bakery products including breads, rolls, and cakes.

Mary Kay

Mary Kay wanted to maximize labor utilization and productivity at the company's Mississauga facility. With the Exacta® warehouse management system, Mary Kay did just that.

Melaleuca

Melaleuca is an international manufacturer of unique health, home, and personal care products. Melaleuca's growing sales accompanied by growing labor was their main problem for order fulfillment. Their existing order fulfillment was inefficient. Their existing Pick To Light (PTL) system required each associate to handle every container even if there were no products to be picked in that area (pick & pass).

MSC

MSC is one of the nation's largest distributor specializing in supplies, tools, and equipment for small and medium-size customers in the manufacturing and metalworking industries. With Distribution centers in four states, MSC has experienced tremendous growth due to acquisition of new companies. They also guarantee same day shipping to their customers.

Navarre

Navarre Corporation is a distributor of PC software, video games and accessories, DVD Video, music based in Minneapolis, MN. Navarre's key focus is providing retailers and publishers with high-quality services for broad, efficient distribution, including vendor-managed inventory, Electronic Data Interchange services, fulfillment services, cross docking and assumed receipt as well as a variety of retailer-oriented marketing services.

Pepsi-Cola Virginia

The Pepsi Bottling Group (PBG) is the world's largest manufacturer, seller and distributor of Pepsi-Cola beverages - some of the world's most recognized consumer brands. PBG generates nearly $14 billion in annual sales. In the United States they account for more than one-half of the Pepsi-Cola beverages sold in North America, and about 40 percent of the Pepsi-Cola system volume worldwide.

Prime Distribution Services

PDS consolidates case level orders for multiple independent food producers into full pallet shipments going to Wal-Mart and other large distribution centers.

Rexam

Rexam is a leading beverage products maker and one of the global leaders in rigid plastic packaging. They produce on average 55 billion beverage products each year in over 50 plants.

Roche Diagnostics

As a global leader in healthcare, Roche Diagnostics needed a state-of-the-art distribution center capable of handling the 9,500 product orders the facility shipped every day. Bastian helped Roche transform their distribution center and improve several key metrics, all while positioning the facility for future growth.

S. Abraham & Sons

S. Abraham & Sons (SAS) had many objectives in mind when they decided to expand operations into a new facility in Greenfield, Indiana. From a corporate perspective the objectives were clear.

Shaklee

Shaklee Corporation, headquartered in Pleasanton, California, is a diversified global consumer products company, including name, research and development technology, and direct marketing. Over the past 45 years Shaklee has become a recognized pioneer and trusted name in the health and wellness industry.

SMC Corporation

SMC Corporation of America is the world’s largest manufacturer of pneumatic automation products. SMC has over 8,900 basic products with over 520,000 variations. Categories of products include: actuators, electronics, fittings & tubing, airline equipment, chillers, valves and vacuums.

Starbucks - Nevada

A major coffee distributor based out of the Pacific Northwest purchases and sells coffee, espresso, pastries and coffee-related accessories through their retail stores, as well as supermarket chains.

Starbucks - Washington

A major coffee distributor based out of the Pacific Northwest purchases and sells coffee, espresso, pastries and coffee-related accessories through their retail stores, as well as supermarket chains.

Technicolor

Technicolor is the world's largest manufacturer and distributor of Blue Ray Discs, DVD's, video games, and CDs, with an annual capacity of 2.1 billion units per year. The 650,000 sq. ft facility in Livonia, MI processes "New Releases" for clients including Paramount, DreamWorks, Microsoft, Warner Brothers, and Walt Disney Pictures.

Tower Automotive

Since their beginning in 1993, Tower Automotive has focused on acquiring three key components in order to become leaders in their field: cutting edge technical capabilities, the best in leadership, and a broad product range.

Undergarment Manufacturer

A major US-based manufacturer has found success for over 150 years as a vertically integrated manufacturer of cotton underwear and outerwear for men, women and children.

The company's new Distribution Center features a $6M + automated material handling system.

USPS

The Indianapolis General Mail Facility recently completed the commissioning of an extensive two floor tray handling system. Postal workers are very happy that they no longer have to handle these trays manually in carts and can now sort the trays in 30% less time.

Virginia Alcoholic Beverage Control

The Virginia Department of Alcoholic Beverage Control (VA ABC) which is located in Richmond, Virginia controls the sales and distribution of alcoholic beverages in the Commonwealth of Virginia.

Wawona

Wawona Packing Company in Cutler, CA is a family owned company that grows, packs, and sells their fruit domestically and overseas. The Wawona label, “Sweet to Eat” is considered one of the top quality labels in the California tree fruit business.

Westcoast Warehousing

Westcoast Warehousing is a third-party logistics provider offering warehousing, trucking, and storage solutions for retail companies throughout California and the west coast. As business increased, the company needed to automate in order to meet the demands of its growing list of clients. Westcoast Warehousing turned to Bastian to automate and improve its picking process.

Zimmer

Zimmer is a worldwide leader in joint replacement solutions for knee pain and hip pain, and provides comprehensive spine care solutions for acute and chronic back pain. The company also provides a broad range of trauma, dental implant, and orthopedic surgical products. Founded in 1927, Zimmer is committed to providing effective techniques in hip replacement and knee replacement for orthopedic surgeons who restore mobility and relieve the pain of osteoarthritis and traumatic injuries.