LEXINGTON, North Carolina – Since 1967, Pallet Resource of North Carolina (PRNC) has specialized in everything and anything for its clients. The pallet recycler and specialty pallet manufacturer has recently upgraded its repair line with the latest equipment from Automated Machine Systems (AMS). PRNC states to its clients, “Any pallet or specialty crating product you can imagine, we can build.” Recent automation efforts have been deployed to help the North Carolina pallet provider follow through on that promise.
The company’s latest equipment upgrade, which includes the Pallet IQ™ inspection system from AMS, will be a key piece of equipment to ensure consistency and technology-based quality verification for customers.
Automated Pallet Inspection – Pallet IQ
Eric McCarson, a sales representative for PRNC, noted, “Automated inspection gives us consistent quality control instead of human eyes, which can have variation depending on the operator and other factors.”
Is the Pallet IQ better than human operators? The answer seems to be yes after only operating for less than a year. Chris Easter, plant manager for PRNC, explained, “It’s still in the learning phase, but the Pallet IQ system is working the way it should. The more the system sees, the more it learns and the better it gets.”
AMS claims that the Pallet IQ inspection system, which uses a combination of 2D cameras, sensors and proprietary software, is the fastest inspection solution on the market. Currently, the Pallet IQ has a cycle time of 3-5 seconds per pallet, according to PRNC. Easter estimated, “We can produce 3,000 to 4,200 pallets per shift.”
PRNC went up to AMS to see the new equipment up close. McCarson stated, “We were impressed by the AMS team and how many technological advancements they had worked into this new line. It is also very user friendly, which is critical from a staffing situation. The new approach automatically manages the flow of pallets to each repair station.”
This new AMS repair line has a pop-up stopper at each workstation. This allows for pallets to be dispensed at each table as long as the people further down the line have a pallet to process. PRNC’s previous repair line was over 21 years old and was showing its age. McCarson admitted, “There have been a lot of advances in technology since that time. We replaced it because it was worn out, and we wanted to upgrade to newer, more efficient technology.”
The new AMS repair line starts out with a conveyor where a forklift loads the pallets onto the line. Stacks are processed through a destacker, breaking down loads one pallet at a time. A human inspector determines if a pallet is good to go, needs to be repaired, or should be sent to the dismantler to produce recycled lumber. Good-to-go pallets head down to the Pallet IQ inspection system to determine which stacker the pallet should be sent to for final collection. Repaired pallets are sent down the line to repair stations. The system automatically dispenses pallets to operators, which reduces the amount of work and strain on the repair operators. Finished pallets are put back onto the line and are sent to the Pallet IQ inspection system. The system determines the pallet quality and tells the line which of the four stackers should receive the pallet.
PRNC sorts for four types of pallets. A premium club grade pallet, an A-grade pallet, and two versions of B-pallets. The club grade has six-inch lead boards, and the standard A has four-inch leads. The higher grade B-pallet has no repair on the center runner. The other is just a typical B-grade pallet. Currently, the company has placed a human quality control operator after the Pallet IQ system just to confirm everything is working correctly in this startup phase.
Why place the pallet inspection unit at the end of the line? Easter explained, “This approach allows us to use the Pallet IQ to inspect the work of our operators as well as track production and determine the quality of cores coming from various suppliers. We can determine what we repair out of each load. We can then go back and discuss core quality and compensation with suppliers.”
The new AMS system takes a lot of the labor out of the process by automating pallet dispensing, reducing the steps that repair operators have to take, automating final inspection, only sending pallets that need repair down the line, etc. McCarson said, “The new process is much easier on our employees and removes a lot of the leg work.”
Mac Grimes, owner of PRNC, agreed, “We’re always looking to make things easier for the employee, from a physical and ergonomic standpoint.”
The Pallet IQ system searches for obvious quality issues, such as broken boards, broken runners, protruding nails, etc. It can also track operator output and help with sorting for various styles and types of pallets, such as rental pallets. In the PRNC system, problem pallets are kicked out for manual repair and handling. Only ready-to-go pallets are dispatched to the stackers.
Pallet IQ Technology
Kris Chayer, president of AMS, has sold a number of Pallet IQ systems to both pallet companies and pallet users. “At the end of the day, our goal with Pallet IQ is pretty simple; make pallet inspection fast, reliable, and straightforward for anyone running the line,” said Chayer. “We want our customers to have confidence in every pallet they sort, repair and produce, without slowing down operations.”
Built around a three-second cycle time, the Pallet IQ is designed for speed and precision. It can handle just about everything from measuring pallet size and checking lead board condition to spotting damaged stringers, repairs, and even nail protrusions down to 1/16 of an inch. That speed makes it a perfect match for AMS’s new High Velocity Accumulator (HVA), which the company believes is one of the fastest stackers on the market today. “When you put the Pallet IQ and HVA together it sets the new standard for speed and quality,” said Chayer.
The Pallet IQ uses a mix of advanced cameras, sensors, and proprietary software to hit those speeds while staying accurate. “We’re always improving it,” added Chayer. “Like anything else in automation, the technology keeps getting better and we’re constantly finding ways to make it even faster and smarter.” Every update AMS makes to the Pallet IQ is about one thing, helping customers move more pallets, more accurately, and with less effort.
Secret Sauce – Customer Service and Specialty Pallets and Crates
In an area of the country known for its barbeque, the secret sauce for PRNC is its specialty wood packaging and pallet capabilities and relentless focus on serving customers.
Not surprisingly, many customers want more for less. Al Hinson, the PRNC sales manager, explained, “Many customers want a new pallet at a used price. And that’s what drives the market as far as what we try to sell. The club grade is our primary pallet that we sell. We get huge demands for that spec. And we’ll ship them anywhere. In fact, we’re even shipping some pallets out to New York.”
Hinson added, “Our ability to do custom work and offer a wide variety of pallets sets us apart from the competition…We get a lot of requests for custom work with a very specific size or quality criteria. And a lot of the other shops around us don’t want to mess with this kind of order.” PRNC makes pallets ranging 20×20 inches to 16-foot long and everything in between. Hinson clarified, “Sometimes we have 35 different variations of one size. It’s all customer specific designs.”
McCarson recalled a recent custom order that had a claims issue with a trucking company. The trucking company asked for four-way access pallets, and within an hour, PRNC had a new concept and samples developed and ready to deliver.
PRNC’s recent investment in automation is making that core competency even better, Jake Parrott, a salesperson for PRNC, explained, “I think some of the new equipment has improved our quality that much more. Our speed and quality sets us apart.”
Hinson added, “A customer calls with a problem, and we have a workforce that has been with us for years and years. We do our best to take care of our employees, and that’s repaid in loyalty. We have a lot of institutional knowledge that helps us serve customers well. And it’s a team effort that can provide that level of service and turn it around quickly.”
New Equipment Strategy
PRNC has changed its philosophy when it comes to equipment upgrades and automation. Easter commented, “We have shifted from a strategy of buying used equipment and trying to make it work for us. Now we focus on new equipment to improve efficiency and uptime.”
Most of the equipment PRNC recently upgraded was to replace older, outdated machines that were wearing out. The company also likes the newer equipment because of the safety innovations that makes processes less hazardous for workers. Besides the AMS equipment, PRNC has invested in a Holtec package saw, a Go Fast notcher, a Pendu block Saw, and an SCMI Sigma S95 panel saw.
PRNC buys a lot of wood on the open market and resaws and cuts it to length, a lot of 2x6s and 2x4s. The Holtec SeleCut V-Series crosscut saw has worked well, giving the company greater production and accuracy than its old saw. This saw came with a board aligner that lines up the edges of the board. Also, employees use a new SCMI Sigma S95 panel saw for cutting plywood panels. PRNC also deploys a drill press because certain customers need bulk patterns built into their pallets.
Working with AMS has been a very positive experience for PRNC. Easter recalled, “The AMS team was really driven to meet our goals and were knowledgeable of the system.” PRNC particularly called out a tech named Micah Farraher. Easter said, “He had had a great understanding of the equipment and could quickly troubleshoot anything that came up and was a pleasure to work with.”
New Generation, Same Basic Customer and Employee Approach
The Grimes family has owned PRNC since Neal Grimes founded the company in 1967. Over the last several years, Neal has transitioned the ownership and control to his three sons Mac, David and Stephen.
PRNC has a lot of customers that have been with the company for 30 years. The longevity is due to their consistent focus on delivering products on-time and meeting customer needs. McCarson stated, “I was under Neal to start with, and now with the transition from Neal to Mac, Stephen, and David, the second-generation of Grimes just picked up right where Neal left off. As far as the sales team is concerned, Mac backs us and gives us the leeway to do what we need to do to retain a customer.”
A major focus for the company over the last few years has been faster delivery time, because many PRNC customers operate 24/7 and cannot afford to be without pallets at any time. Mac Grimes acknowledged, “We have made just-in-time delivery a key focus for us. This involves predicting customer needs based on previous experience, storing safety stock and ready-to-go inventory for some customers, and offering vendor-managed inventory services. We try to keep some supply of our most popular sizes in stock at all times.”
In addition, the company runs a second shift that operates in the evening. This shift exclusively cuts material for the main shift to process and turn into pallets. PRNC has deployed this strategy for years.
Employee longevity is a big advantage for PRNC. The management team works to retain staff by offering flexible shifts and being considerate of unexpected life situations that their staff may encounter. Currently, the company has 80 employees. Three times per year (Cinco De Mayo, Labor Day and near Christmas), the company hosts big food celebrations to recognize the team and just say thanks. The Grimes family participates in these employee celebration meals and helps serve the food.
AI Innovation & Evolution
The company’s first foray into using artificial intelligence (AI) is the Pallet IQ inspection system. It uses AI to help the system learn more about the company’s core supply and specifications.
Grimes said, “I’ve got a 30-year military background, so when it comes to AI, I’m also thinking about it from a national security perspective. The rise of China and their influence over information systems gives me pause about the programs that we’re using.”
However, Grimes trusts AMS and the way they are initially deploying AI. He knows there will be risks and greater rewards in the future. He also knows that his customers will be using AI tools as well. Grimes acknowledged, “Other companies are going to be adopting AI, and I’m sure they’re going to be using algorithms to influence their purchasing decisions. And so understanding that and knowing how to navigate that, I think, is going to be important.”
The PRNC leadership believes its strong sales team will continue to be a difference maker when it comes to truly understanding clients. Grimes said, “Often, when a remote corporate headquarters wants our local client to change vendors, we’ve benefited from that personal relationship where the local company will push back and say, ‘No, we’re not going to go with the national bid. These are the guys that take care of us day in and day out, and we’re going to stay with Pallet Resource.’”
Editor’s Note: For more information on AMS and its services, please visit www.automatedmachinesystems.com, call (877) 267-8384 or e-mail solutions@automatedmachinesystems.com. To order pallets from PRNC, call (336) 731-8338 or e-mail sales@prnc.com.
