Warehousing Insights | Material Handling Systems cross | Warehousing Insights | Material Handling Systems - Part 2
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The Easiest Win in Automation: Machine Loading and Unloading

August 28, 2025

conveyor integrated into mill machinery

Machine load-unload automation is one of the most profitable and straightforward automation opportunities in both warehouses and factories. It improves productivity in two key ways:

  • Reducing labor needs: Repetitive manual loading and unloading is replaced with automation, cutting costs and reducing injury risk.
  • Increasing machine uptime: Machines stay productive with predictable cycles, eliminating idle time between parts.

The real payoff is in uptime. When unloading and reloading are automated, a machine rarely waits for an operator. Preparatory work and staging can happen offline, so the next part is always ready. In ideal cases, production rates can increase dramatically without additional equipment investments. Focusing on these key points, where automation can have outsized impact is the key to smarter, better operations. These tend to be low value, but critical processes that should be automated so that labor can be reallocated to more critical functions.

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Posted in Automation, Labor & Efficiency|

Insights August 2025: Employee-Ownership & Manufacturing

August 19, 2025

Morning coffee with Cisco-Eagle photo
This month, we discuss strategic warehouse execution system implementations with Savoye–how to scale, how to match real-world processes. Additionally, the impact of employee ownership on manufacturing and its potential as a key to succession for small and mid-sized manufacturers. Also, more on industrial construction and the softening demand for manufactured products.
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Posted in Industry Insights|

Cisco-Eagle Announces 2025 Core Values Awards

June 26, 2025

Cisco-Eagle Core Values Awards Winners for 2025
Cisco-Eagle named its inaugural Core Values award winners in June 2025. These are employee-owners who embody our core values–the principles we aspire to. Those values were established over thirty years ago and remain unchanged since. “They are universal and timeless,” said CEO Darein Gandall. Our founder, Warren Gandall, has often said that he wants to treat his suppliers, customers and employees the way he wants to be treated.

Our values reflect that vision, and so do the 2025 winners of these awards.

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Posted in ESOP & Company News|

Behind the Gates: A Conversation with Markus Green on AisleCop Gen5

June 10, 2025

AisleCop Gen5

When pedestrian safety meets forklift traffic, there’s no room for error. That’s where AisleCop® comes in. And now, with the launch of Gen5, Cisco-Eagle has made it faster, easier, and more scalable to deploy than ever before.

We sat down with Markus Green, head of our Safety Automation department, to talk about what’s new, why Gen5 was developed, and how it’s helping safety managers and operations teams move faster.

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Posted in Forklift - Pedestrian Safety|

Best Practices for Loading & Unloading Pallet Conveyors with Forklifts

May 20, 2025

forklift unloading pallets from the end of conveyor line

Loading and unloading pallet conveyors with forklifts is an everyday, all-day task.

Done right, it’s fast and efficient. Done wrong, product damage, collisions, injuries, and workflow bottlenecks happen. I’ve seen it in dozens of warehouses, even in highly automated operations, and most of them tend to bridge the shipping dock and the end conveyor lines with forklifts (these days, AGVs and AMRs often do this work). Pallets are large, heavy and in motion when they’re transported on conveyors. That combination of size, pressure and movement can result in damage or injuries when not properly controlled.

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Posted in Conveyor Optimization|

Evaluation: Pallet Rack Storage Density, Access, Safety and Costs

April 24, 2025

High bay selective rack pallet storage.

Just how many pallets can you store in a 100′ x 100′ area? It can range from not that many–X with selective racks that let you pick or place any pallet at any time–or “Y” using incredibly dense, using pallet flow or drive-in systems that restrict how and when you can access pallets. The balance between storage density and selectivity is always critical, but there are other factors in play: cost, efficiency and safety.

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Posted in Pallet & Warehouse Racks|

2025 Warehousing Survey

April 15, 2025

warehouse workers reviewing production flow

It started with a simple question: What’s your biggest operational challenge?

We didn’t expect leaders in manufacturing, warehousing, and distribution to respond with such clarity, but they did. And what we heard wasn’t vague. It was precise, urgent, and reflective of a sector that’s evolving in real time.

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Posted in Industry Insights|

An Ergonomic Labor Strategy

March 4, 2025

worker in hard hat pushing box

As we’ve discussed previously, labor is hard to find these days – and it will get harder every year. Cultivating your labor pool eases the need (and high costs) of hiring, training and retaining workers. One of the best ways to do this is to optimize as much as possible for ergonomics.

As the saying goes, what you appreciate appreciates.

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Posted in Safety & Ergonomics|

Automation and Space: Conveyor Layouts

February 4, 2025

Conveyor system extends overhead, above a busy shipping area to conserve floor space.

Above: Belt conveyors hang from the ceiling of a busy e-commerce distribution center, feeding shipping operations from a pick module while leaving the space below for traffic and shipping activities.

Conveyor systems transform picking, transport, assembly, and more, but occupy space in fixed positions. Tight layouts, low ceilings, facility structures and equipment compromise and compete for that square footage.   Don’t worry, though—there are creative ways to work circumvent those limitations–and in some cases make them strengths.

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Posted in Conveyor Optimization|

Double-Post Pallet Rack Systems: When, Why and How

January 7, 2025

Pallet rack system with two posts used for each rack bay

Most pallet rack systems are installed with a starter-adder design, which shares a common rack upright between consecutive storage bays. The alternative is a double-post rack system, where each bay has two independent uprights. Most of the time, starter-adder is used because it’s more economical and uses space more efficiently.

Given that it’s costlier and uses more space, why–and where–would you use a double-post design?

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Posted in Pallet & Warehouse Racks|

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