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Automated Solutions Power Pine Glo’s Packaging Operations
Making operations shine
There is nothing like increased throughput to make a business thrive. However, higher production volumes require advanced automated operations to ease the burden on employees. That’s why Pine Glo partnered with Schubert to implement a pre-configured case packing solution, enhancing operational efficiency of the family-owned business.
Pictures: Gerhard Schubert GmbH
Pine Glo, founded in 1979 by Robert Diehl, is a true family business. It all began in the Diehl family’s bathtub with 20 formulas before creating a hospital-grade disinfectant that also smelled good. Based in Zebulon, North Carolina, Pine Glo has grown into an industrial sized facility while remaining deeply rooted in family values. The family’s dedication has grown Pine Glo’s loyal customer base, earning spots on shelves at major retailers like Dollar General, Family Dollar, and Walmart. What started as a family dream has become a multi-generational business success story.
Shipping over 20 million bottles of cleaner annually across the United States presents a significant case packing challenge, especially since Pine Glo has relied on manual labor processes until now. With expansion plans on the horizon, the company recognised the need for a more efficient, labor-saving solution. To support growth and improve operations, Pine Glo aimed to increase throughput by automating their processes. “Our goal was to reduce manual labor, increase throughput, and improve overall job satisfaction,” says Matthew Diehl, President of Pine Glo Products.
Pine Glo markets cleaning products in many bottle formats.
An Overseas Solution for Pine Glo’s Growth
Pine Glo turned to Schubert when they were seeking packaging equipment to reduce labor costs and increase throughput to meet the growing demand for their cleaning products. Additionally, they needed a versatile packaging machine that could be quickly converted to different case formats using easily interchangeable tools, accommodating the wide range of bottle sizes and uniquely shaped spray bottles that are often difficult to pack due to their shape. “We were familiar with Schubert and their reputation for building reliable, long-lasting equipment, which is well-known across industries here in the U.S.,” says Steve Williams, Production and Engineering Manager, Pine Glo Products.
It comes as no surprise that Schubert’s pledge to outstanding packaging technology played a significant role in Pine Glo’s decision-making. “At the end of the day, we’re investing in reliability. We want equipment that can serve future generations, not something that needs to be replaced in just a few years,” says Diehl.
After assessing the company’s needs, Schubert’s lightline pre-configured Casepacker emerged as the ideal solution. With reduced complexity for quick and easy changeovers, it comprises adjustable tooling to handle Pine Glo’s various case sizes with traditional cap styles and spray tops. “The lightline’s customisable in-feed and out-feed options are crucial for maintaining efficiency, consistency, and accuracy in our packaging lines, supporting our shift toward automation,” says Williams. “And Schubert’s shorter lead times for the lightline provided faster machine delivery, allowing us to meet our rapidly growing demand”, continues Williams.
Pine Glo packs up to twelve bottles per case with the lightline Casepacker.
Pine Glo Enhances Efficiency with Schubert Case Packing Integration
Schubert installed three lightline Casepackers at Pine Glo’s Zebulon facility. “We were excited to integrate the case packing machines into our daily operations and see their impact on current processes. No matter what challenge we faced, Schubert was ready to provide a solution,” Diehl says. The engineering experts from Crailsheim supported Pine Glo in achieving a harmonious line layout. Considering the Casepacker’s fixed magazine location they added a 90° curve to the bottle in-feed to improve the process flow. Additionally, Schubert collaborated with Pine Glo, along with its case and glue suppliers, to improve the stability of the cases, addressing issues with them popping open after gluing.
The fully automated workflow reduces manual intervention while maintaining the flexibility to pack a variety of case configurations and bottle sizes. Once the bottles are filled, capped, and labeled, the lightline Casepackers take over, first erecting the shipping cases, then loading the bottles with Schubert’s F2 robots. These highly agile robots handle the bottles with precision, minimising the risk of product damage. The entire case packing line was designed with flexibility in mind, accommodating various pack sizes, ranging from four to twelve bottles per case.
After the bottles are loaded, the cases are sealed using adhesive hot-melt glue, ensuring a secure and reliable closure. The sealed cases are then automatically discharged onto a conveyor system, which transports them to a separate palletising unit. At this stage, the palletiser organises and stacks the cases onto pallets, optimising load stability and preparing them for efficient transport or warehousing.