C&H Sugar
System Summary
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.
Business Challenge
- ASAP had to upgrade C&H Sugar’s 16-year old ASRS, WCS 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 (ERP) instance.
Key Technologies
- ASAP’s Exacta Warehouse Management Software (WMS) to maintain inventory control across 6 aisles of Litton ASRS housing 15,400 locations (WMS).
- ASAP’s Exacta Connect – Real Time interface to SAP.
- Exacta ASRS windows based GUI, Automated Order Routing Software, and ControlLogix platform v.13.0 (WCS).
- 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.
- Accusort Model 24 Series Overhead and Model 22 Series II Line Scanners.
Results
ASAP’s solution yielded a seamless transition with no down time to C&H Sugar’s production or shipping. Exacta WMS and WCS 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.
