Everest Foods and Daifuku: A Partnership for Unmatched Efficiency

In the world of spices, where every pinch adds depth and flavour to countless dishes, Everest Food Products Pvt. Ltd. has established itself as a leader. With a commitment to quality and an expansive global reach, Everest exports varieties of masalas to more than 60 countries. But as demand grew, Everest faced a new challenge: how to expand their operations while keeping quality and consistency on the menu. Enter Daifuku, a partner that helped Everest serve up a smarter, more efficient way to manage their growing business.

The Everest Challenge: A Need for Transformation

As Everest’s reputation for quality spices spread globally, so did the demand for their products.  Managing different products in more than 240 sizes while maintaining the freshness of perishable goods was becoming increasingly difficult. The manual processes that had served them well for years were no longer sufficient. Loading a single truck could take up to six hours, a delay that was unsustainable given the need to dispatch more than 30 trucks daily. Everest needed a solution that could streamline their operations, reduce errors, and increase efficiency.

The Daifuku Solution: A Path to a Smarter Warehouse

Recognizing that Everest needed a fresh approach to meet their growing demands, Daifuku stepped in with a recipe for success. Their solution? An Automated Storage and Retrieval System (AS/RS) that would serve as the backbone for Everest’s new, smarter warehouse.

Phase 1: Laying the Foundation
The first phase of the project focused on establishing a robust foundation. Daifuku introduced an Automated Storage and Retrieval System (AS/RS) that included cranes for both single-deep and double-deep storage. This system, along with Daifuku’s industry proven WareNavi warehouse management software, provided Everest with more than 6500 pallet locations, allowing them to store tons of raw materials—well beyond their initial target. The system also offered real-time insights into inventory, drastically improving the efficiency of material retrieval and overall productivity.

Phase 2: Scaling for Recipe
As Everest continued to expand, Daifuku scaled the system to meet their growing needs. The second phase involved adding nearly 3,000 more pallet locations while ensuring that operational downtime was minimized to just seven days. This expansion doubled the system’s throughput capacity, enabling Everest to keep pace with increasing demand without sacrificing speed or accuracy.

Phase 3: Future-Proofing the Warehouse
The final phase was all about preparing for the future. Daifuku added five more double-deep AS/RS cranes, bringing the total storage capacity to over 10,000 pallet locations. The system’s height was increased to 29 meters, maximizing the use of vertical space. With the ability to handle approximately 250 pallets per hour, Everest’s warehouse was now equipped to support the company’s continued growth.

Achieving Excellence Through Daifuku’s Automation

The impact of Daifuku’s AS/RS system on Everest’s operations was nothing short of transformative. By automating key processes, Everest achieved a 400% increase in processing speed, reducing truck loading times from six hours to just two. The system’s uptime consistently exceeded 95%, ensuring that Everest could meet its delivery commitments with reliability and precision.

Daifuku’s solution also introduced capabilities that Everest had not previously enjoyed. With real-time inventory management, Everest could ensure that every spice they produced was fresh and ready for delivery, maintaining the high standards that their customers had come to expect. Errors in dispatch were virtually eliminated, and the entire process became more streamlined, freeing up Everest’s team to focus on more strategic tasks.

Daifuku’s custom touch drives Everest Foods forward.

Everest chose Daifuku not just for their technology, but for their deep understanding of Everest’s specific challenges. They didn’t just install a system; they created a partnership, working closely with Everest to ensure that their warehouse was ready to meet the challenges of today and the opportunities of tomorrow.

Daifuku’s commitment to excellence didn’t end with installation. They provided ongoing 24/7 online support, training, and maintenance, ensuring that Everest’s team was always equipped to manage the new system effectively. This level of support was critical in helping Everest not just adapt to change, but to thrive in it.

Growth on the Menu: Everest’s Path to Success with Daifuku

Everest’s journey to a smarter warehouse is a testament to how strategic automation can drive growth and operational excellence. With Daifuku’s AS/RS system, Everest has transformed their operations, ensuring that they can continue to bring the rich Flavors of India to tables around the world without missing a beat. As Daifuku and Everest look forward to the Anuga FoodTec India event, the theme of "Growth on the Menu" resonates strongly, reflecting the shared commitment to innovation, collaboration, and quality.

Ready to put growth on your menu? Book your appointment with Daifuku experts today and discover how we can help you cook up success with cutting-edge intralogistics automation. Visit us at Hall 1 Booth B25 at Anuga FoodTec India, Bombay Exhibition Centre, Mumbai, from 28-30 August 2024. Let’s make your warehouse the next transformation story.

Email: daifuku_solutions@vega.daifuku.com

Phone: +91 8007587362