Imagine having access to a resource that can assist you in transforming logistical challenges into streamlined processes. Our latest case study dives into the journey of Channel Prime Alliance (CPA) – a distinguished plastics manufacturer – as they overcame a complex logistical hurdle with the innovation and expertise of Murphy Logistics Solutions, a long-time member of the Associated Warehouses (AWI) network. If you are contemplating or currently leveraging third-party warehousing services, this story is a must-read. Discover how a strategic partnership led to streamlined operations, cost savings, and an enhanced client relationship, showcasing the profound impact a dedicated logistics partner can have on your business success.

BACKGROUND

Channel Prime Alliance (CPA), based in Des Moines, Iowa, distributes plastic resins and elastomers across various industries, including automotive, healthcare, consumer goods, packaging, agriculture, and construction. Since 2017, CPA has partnered with Murphy Logistics Solutions to serve their clients in the Twin Cities area.

Wilbert Plastic Services, a CPA client located in Minnesota, manufactures plastic components and assemblies through injection molding and thermoforming processes. Wilbert used palletized supersacks, each weighing roughly one ton, to receive CPA’s plastic pellets. These were then unloaded at their White Bear Lake facility for processing into final products. Over time, it became evident that Wilbert Plastics needed a more efficient delivery process to reduce the footprint, labor, and handling costs associated with intaking products from the bulk sacks.

THE CHALLENGE

Wilbert faced several challenges with their delivery process:

• Labor Intensive: Unloading supersacks required significant labor.
• Handling and Disposal: Managing empty supersacks and pallets was cumbersome.
• Inconsistent Deliveries: Inconsistent delivery schedules led to employee idle time and wasted resources.

Recognizing the inefficiencies, Wilbert approached CPA and Murphy Logistics for a solution to streamline their delivery process and reduce operational costs.

THE SOLUTION

Murphy Logistics Solutions, in collaboration with Channel Prime, devised an innovative bulk truck system including the following key components.

1. Hopper System Implementation: Supersacks were emptied at Murphy Logistics’ campus into an industrial hopper, which fed pellets into a bulk truck using a vacuum pump.
2. Labor Redistribution: Murphy’s specialized team managed the labor-intensive tasks of converting supersacks to bulk, handling pallet disposal, and operating the hopper system. This required a team of three: one fork operator and two warehouse associates, who could fill a truck with 48.5 thousand pounds of material in under an hour.
3. Hopper Bin Development: Channel Prime provided a cleaned and modified hopper bin suitable for bulk truck loads.
4. Process Optimization: Ensuring the hopper bin size was optimal for handling, adjusting hose diameters for effective flow rates, grounding the hopper to address static issues, and developing Standard Operating Procedures (SOPs) for seamless operations.

THE RESULT

Implementing the bulk truck delivery system led to significant improvements:

• Labor Reduction: Wilbert no longer needed labor for unloading supersacks, significantly reducing labor costs.
• Efficiency Gains: The new delivery process was smoother and required less handling of supersacks and pallets.
• Cost Savings: The efficient process saved time and reduced labor costs. Space saved from eliminating supersacks and pallets was reallocated to manufacturing, improving core operations

ADDITIONAL BENEFITS

• Employee Utilization: Murphy’s consistent delivery schedules ensured better utilization of Wilbert’s workforce, reducing idle time.
• Safety Considerations: Specialized equipment, such as inverted forks, ensured safe handling of supersacks.
• Environmental Impact: Murphy’s environmental initiatives included reusing odd-sized plastic pallets, demonstrating their commitment to sustainability.

TRANSFORMING LOGISTICS INTO OPPORTUNITIES

The success story of Channel Prime Alliance and Murphy Logistics Solutions demonstrates the transformative power of strategic logistics partnerships. By innovating with a bulk truck delivery system, Murphy not only streamlined Wilbert Plastic Services’ operations but also showcased the remarkable impact of tailored logistics solutions. This case study is an example of how experienced and vetted 3PL providers can drive efficiency, reduce costs, and enhance overall business performance. The collaborative effort didn’t just solve a problem—it propelled Wilbert Plastic Services into a new era of operational excellence, proving that with the right partner, any challenge can be turned into an opportunity for growth and success.

CONCLUSION

If the journey of transformation outlined in this case study resonates with you, imagine what a strategic partnership with a dedicated third-party logistics provider like Murphy Logistics Solutions could do for you. At AWI, we specialize in helping you find the perfect logistics services partner for your unique needs, whether it be through outsourced logistics, third-party warehousing, or comprehensive warehousing and logistics services.

Contact us today to learn more about AWI and all of the ways we can assist you in solving your logistics challenge