ploy | Warehousing Insights | Material Handling Systems - Part 3
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Insights: Labor Balance in an Aging Society

July 3, 2025

Cisco-Eagle Notebooks

In 2025, the U.S. labor market is undergoing a significant demographic shift. Approximately 4.18 million Americans reach retirement age this year (about 11,400 turn 65 each day). The Bureau of Labor Statistics projects that the labor force will grow at a modest 0.4% annually from 2023 to 2033, reaching 173.3 million by 2033. The problem: we’ll need to fill 192 million job openings, according to the Bipartisan Policy Center.

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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|

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|

Package Shipping Fee Increases: How to Cope with Surcharges

January 28, 2025

Morning coffee with Cisco-Eagle photo

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Posted in Industry Insights|

Loading Docks, Security and Truck Drivers

January 14, 2025

Truck drivers at the receiving docks of a busy warehouse

Truck drivers often need to enter warehouses when they deliver or pick up shipments. When they do, many warehouses have installed secure driver cages that let the driver into the facility, but not into the building at large. This can seem “driver-unfriendly” because they contain the driver. However, there are good reasons to install them while ensuring drivers have a good experience at your facility.

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Posted in Docks & Shipping|

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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