Fatigue and Frustration

Before Grain Millers had a TOPLINE, its people were shouldering all the weight in a manual bagging system. The strain was beginning to show, not only in the workforce but also in the company’s bottom line. The manual system required operators to move bags that weighed anywhere from 25 to 50 pounds, weigh each bag to ensure accuracy, take the bag through heat sealing and, finally, place it on a pallet.

“It was a tedious and extremely tiring process,” Selby said. “It really took expertise to properly run the manual machine, and it was extremely labor intensive work.”

The physical strain left operators fatigued, often with sore arms and backs. In addition, the system required two or three operators at any given time. In a typical workday, operators would rotate out and take frequent breaks to keep fatigue at a minimum. That created another problem. The constant pauses and downtime meant inefficient production and lower bag filling rates.

The Grain Millers team knew it needed to find a solution, one that would increase production efficiency by decreasing labor requirements. The company’s research led to the TOPLINE, a machine that seemed like the ideal solution. Even so, Grain Millers explored all its options. “It seemed like we just lucked out finding the TOPLINE, so we didn’t stop there,” Selby said. “We communicated our needs to several manufacturers and asked them to let us know how their bagging machines could meet them. At the end of the day, we couldn’t find a system that fit what we were looking for better than the TOPLINE from Haver Filling Systems.”

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