C&H Sugar

System Summary

C&H Sugar produces cane sugar and molasses for the 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.

Business ChallengeC&H Sugar HMI

  • ASAP had to upgrade C&H Sugar’s 16-year old AS/RS, Warehouse Control Software and Controls System Software without slowing down production.
  • Existing system relied on an obsolete and unsupported software package and VAX hardware for their 24X7 operations.
  • ASAP had to include a real time interface to C&H Sugar’s SAP instance.

Key Technologies

  • Exacta Warehouse Management Software to maintain inventory control across 6 aisles of Litton AS/RS housing 15,400 locations
  • Exacta Connect – real time interface to SAP
  • Exacta AS/RS windows based graphical user interface
  • Warehouse Control Software, and ControlLogix platform v.13.0
  • Exacta transfer station, buy in station, and mix pallet build and inspection station.
  • Exacta “3A In”, “Conventional In”, and “Manual In” stations to handle rebuilds and out of tolerance pallet builds.
  • Exacta loop and ship rejects to accommodate no-reads or mis-reads
  • Mettler-Toledo on-the-fly pallet dimensioner and in motion check weigher
  • ID Technologies on-the-fly pallet Print and Apply applicator

C&H Sugar

Results

AS/RSASAP’s solution yielded a seamless transition with no down time to C&H Sugar’s production or shipping. The Exacta Warehouse Management System and Exacta Warehouse Control System increased throughput by 27% with 115 trailers per day vs. 90 trailers per day in the previous system. Packaging efficiencies have increased 100%, and C&H Sugar no longer experiences backups, down time, and receive loop saturations.