No two Viking customers are the same. Each pallet manufacturer has some differences even though they may be in the same industry. From the lumber they use to the pallets they make to the setup of the facility to the production and versatility requirements, each installation is somewhat unique.
Viking Engineering & Development Inc. has developed a reputation for reliability and customer service. Four customers share their experiences from a recycler just jumping into automated pallet nailing to a large manufacturer running six Turbo 505 lines. Find out how Viking’s collaboration with customers is paying off in terms of labor savings and production efficiency.
If It Works Great, Don’t Change It
Wooden Pallets Inc. in Silsbee, Texas is in elite company when it comes to running a lot of Viking Turbo 505 lines. The company’s attitude seems to be, “Why mess with a good thing.” Currently, Wooden Pallets operates six 505s, and another one is on order for delivery this month.
Diron Holt, the sales and purchasing manager for Wooden Pallets, admitted, “Viking has been around so long that our operators know the machines and can program them easily. Viking has always worked well for us, and we didn’t want to mess with a good thing.”
The company produces 125-130 truckloads per week. That’s a lot of pallets. Holt said, “Our Turbo 505s help us keep production cost low compared to the competition. We can produce more pallets with fewer employees than many other pallet manufacturers in our region.”
The Turbo 505 averages 1,800 pallets per eight-hour shift with two change-overs. Some Viking customers achieve even higher production numbers. Holt stated that Turbo 505s run without problems and allow for quick changeovers. This ensures that the 180 employees at Wooden Pallets can do their job as efficiently as possible.
Holt commented, “Our success comes from building relationships with customers and taking care of their needs. The reliability of Viking nailers helps us to keep our customers happy.”
Wooden Pallets operates its own trucking fleet and now offers services beyond the Houston area to reach even to the Dallas/Ft. Worth region. Every step of the way, Viking has been there to help Wooden Pallets grow.
Gruber Pallets Launches into Automated Pallet Nailing with Its First Champion
Through the years, the Viking Champion has become a workhorse in the pallet industry. The machine’s strong reputation is what sold Gruber Pallets in Lake Elmo, Minnesota on the Viking Champion. A recycler with a commitment to quality, Gruber opted for the Viking Champion due to its strong reputation as well as the close proximity of Viking.
Luke Gruber, the general manger of Gruber Pallets, said, “Primarily, we’ve been dipping our toes into building new pallets, and we wanted to transition from hand-built pallets to automation. Our goal has been more consistency and higher production.”
Luke’s father, Dale Gruber, is the founder of the company and he drove the decision to select Viking. Luke explained, “One of the primary reasons we went with Viking over other suppliers is the company’s amazing reputation. That solid reputation really sold my dad. He is all about creating relationships and having people that you can trust. Viking has been reliable in terms of its sales and support. Viking’s techs are really good.”
Because the company didn’t have an operator for the first few weeks, Gruber turned to Luke to tackle the installation and training process. He said that he was the first person trained on the machine at the company, and he credited the Viking techs with getting him quickly up to speed.
Gruber Pallets took possession of its Viking Champion in December 2018. Going from hand-built pallets to automation, Luke said that operators have to climb the learning curve of control screens, troubleshooting jams and basic lean manufacturing principles. Luke said, “Automation is more complex than just using pneumatic tools and a hammer. But once you get the knack of it, Viking’s automation is user friendly, and the company offers world class support.”
In addition to the Viking Champion, Gruber Pallets also purchased the optional lift station. Luke explained, “We didn’t want the operator to have to bend over excessively. We wanted to reduce worker strain and maximize the output of the machine.”
Gruber Pallets is happy with the progress in just a few short months and believes the new machine will meet its production targets in the coming months. It is using the machine to produce mostly standard-sized pallets, such as 48x40s. Luke affirmed, “We are happy with our progress, but we obviously always want more.”
Power Recycling Dives into Pallet Manufacturing Producing Combos with Recycled Lumber
Seeing a Champion run is what sold Gary Donadio, president of Power Recycling, on the capabilities of the Champion. Having developed a strong reputation as a recycler, Power Recycling has branched into new pallets in a big way.
Donadio said, “I saw the capabilities of the Champion a few years ago when I visited Nazareth Pallet in Pennsylvania. It’s eye opening to see the capabilities of what the machine can do in terms of combos and recycled lumber.”
Power Recycling’s first Champion was a slightly used machine that was basically brand new. It added the first unit in February 2018, and over the summer, the company decided to add a second machine and third one. From a financial perspective, the Champion made sense. Donadio figured the machines would easily pay for themselves in three years or less. Each machine saves at least one person.
Speaking about the performance of the Champions, Donadio admitted, “We’re very happy with the machines. We are still working out a few kinks on our end. These machines are capable of doing combos and using recycled lumber. We have to change our mindsets a bit and improve our sortation process.”
Donadio added, “We already are doing combos on the machines so we feel very confident that we’re going to get to the point where we’re doing full recyclable pallets on the machines. I expect we will reach that point within a month or so.”
Recycled lumber is a key to efficiently produce like-new pallets. Committed to recycling, well over 50% of the new pallets produced by Power Recycling involves reclaimed lumber. Donadio said, “We really had to find a machine that is truly capable of utilizing recycled lumber. Viking has been around a long time, and the Champion has a great reputation.”
Champions are single-operator machines with a lot of versatility. Power Recycling is getting 400-450 pallets per shift when using only new lumber. With recycled materials, the machine is reaching 300-350 per shift although the company hopes to get even more efficient.
Donadio explained, “With recycled material you’re going to get variations and you need to sort for certain parameters. For example, the thickness of the stringers has to be within certain parameters. You may be able to get away with an eighth- or a quarter-inch variation for manual production using jigs. But you need more consistent thickness with automated production.”
An important part of the process is getting a machine installed and operators trained. Gary stated, “Viking offers excellent support from the install to training and operation. Viking has been a class act organization. Scott [Ellefson] and the support team are very supportive. Viking definitely stands behind its products.”
Power Recycling liked the strong reputation of the Champion. Donadio said, “One of the nice aspects of the Champion is that it isn’t a new machine. It’s been tried and proven. That explains why the ramp up phase is so easy.”
Donadio added, “In our 43 years in business, we certainly have pioneered some machinery innovations, and that process while sometimes necessary certainly isn’t fun. It’s nice to get a machine that’s proven out in the industry that’s almost plug and play.”
Power Recycling likes having three separate machines because each line can focus on a particular type of pallet with limited changeovers required. One produces strictly new pallets with new lumber. Another does combos, and the third machine focuses on custom pallet sizes. Recently, Power Recycling has transitioned to making more custom sizes.
Donadio commented, “Look at the core market over the last 10 years; the quality of cores, we all know, is diminished dramatically. There’s no standardization with a standard GMA. Everybody is out there battling over available cores and pricing has just gotten ridiculous. We’ve come to the realization that we’re not going to be dictated by the core market. Our Champions give us the versatility we need to succeed now and in the future.”
Packaging Specialists Produces Heavy-duty Pallets on Viking Lines
Producing heavy-duty pallets for tough jobs is something that Viking lines can handle. Packaging Specialists of Olivehurst, California knows this firsthand. Gary Allen, owner and president of Packaging Specialists, said that his company manufactures mostly heavy-duty, four-stringer pallets on its two Viking Champions and one Viking Duo-Matic. Most of the designs use new lumber although the Champions can produce pallets with recycled boards.
The Viking machines run well if you do standard maintenance. Allen said, “We do all of our own basic maintenance on the Viking nailers. There are just some things you have to do to ensure top production. For example, on the Duo-Matic you have to maintain the chuck springs, jaws, drivers and picking mechanisms on a regular schedule.
Allen is considering upgrading his Duo-Matic to a Viking 403, which comes with a more modern PLC and operator controls.
When the machines need a part, Allen raved about Viking’s parts and support staff. He said, “We always had a great rapport with Jim Gookin in the parts department, and he’s now retired. Dan Macheledt has taken over for him and is just as capable and friendly as Jim was in the past. Viking service pros totally take care of you if any problem or parts issue arises.”
Viking has also added Chad Kolar to work alongside Dan to provide fast customer service phone support.
Packaging Specialists first discovered Viking through a relationship with Mark Mitchell and his wife who worked in the parts department for Viking. Packaging Specialists transitioned from the cable reel business to the pallet sector in the 1980s. It shortly thereafter bought a Champion and has been a loyal Viking customer ever since.
Packaging Specialists has developed a strong reputation for pallet manufacturing although it also does a small amount of pallet recycling. A key to the company’s success has been its commitment to customer service. Allen commented, “Service and quality help set us apart. We deliver full truckloads of pallets with a less than eight-hour notice. That kind of service would be difficult without our Vikings.”
You must have reliable machinery if you want to provide reliable service to your customers. Allen added, “Viking does extremely well in terms of its support. Mark Mitchell, our sales representative, is particularly good in terms of responding to requests in a timely fashion.”
Why Viking Has Changed Its Sales Process
Over the last year, Viking has transitioned from a salesperson-based approach to regional sales territories. Kurt Larsen, president and CEO of Viking, said, “Viking had used territories in the past and over the last few years I have been moving us back to that approach. Viking now has the sales and service team depth to make the change.”
Larsen further explained, “We want to develop a deeper understanding of our customers’ goals and needs and work more closely with them on solutions. The solutions are not always as simple as they may have been in the past. Automation and integration of systems and processes are required. That takes repeat visits, listening and working through options and testing ideas. The needs of pallet manufacturers are changing faster than in the past, and we want to be able to collaborate with them on unique solutions. Sales personnel dedicated to each region allows us to offer a more holistic approach and more discussions in person at customer locations.”
One of Viking’s regional sales representatives has just celebrated his 40th anniversary with the company. Mark Mitchell, 58, will mark 36 years in February, but he also was employed for four years with the predecessor business, Viking Pallet. Mark Mitchell, who has the distinction of being the last remaining Viking Engineering employee from the predecessor business Viking Pallet, currently serves as sales and service manager for a region that encompasses states in the West, Rocky Mountain and Pacific Coast regions.
The three other sales representatives are Scott Ellefson, who manages the North Eastern Atlantic region; Kenneth Rose, who oversees the South Atlantic and Gulf region; and Darren Bergstrom, who handles the North Star and Great Lakes region. The regional sales reps are led by Sales Manager Dave Anderson, who also spearheads international sales. The Viking sales team has over 120 years combined industry experience.
Voyager Update on the Next Generation of Viking Technology
Part of listening to customers is collaborating to create the future. Viking’s Voyager is the latest product in the pipeline. It offers high-speed nailing, the potential for automated lumber feeding and improved ergonomics for operators.
Larsen stated, “The Voyager design was driven by customer feedback about reducing the ergonomic load and number of lumber loading operators.”
Larsen added, “The Voyager machine is making great pallets, just not at our desired production level. We have identified the constraint and in the next few months we will be testing a new board positioning system design.”
Viking has developed a reputation for reliable machinery, and it doesn’t want to rush something to market until it is ready to go. Larsen affirmed, “We are committed to a successful launch of this product and so we are being patient and taking the machine through a thorough validation process. We can’t wait to load deck boards into the machine with robots, conveyors, unscramblers and crank out pallets!”
