High-Performance RPC Crate Handling Automation for Fresh Produce Packing Operations
- 13 hours ago
- 4 min read
Delivering Reliable Crate Handling Automation
Fresh produce packing operations rely on a continuous and reliable supply of crates to maintain productivity across packing lines. When crate preparation becomes manual or inefficient, it can create bottlenecks that impact throughput, labour efficiency, and operational safety.
To address these challenges, Fibre King, through its crate handling automation brand Oryx Automation (established in 2007), delivered a fully automated RPC crate handling system for a major fresh produce facility in South Australia.
The solution was engineered to automate crate preparation, improve line efficiency, and support the high throughput demands of modern produce packing operations.
“Reliable crate supply is essential to maintaining packing line throughput. Oryx Automation crate handling systems ensure a consistent flow of crates to support high-volume fresh produce operations.” - James Windsor, CEO Fibre King.
The Challenge
As production volumes increased, the facility required a more efficient way to prepare and supply reusable plastic crates (RPCs) to its packing lines.
Manual crate handling was becoming increasingly inefficient and presented several operational limitations:
• High labour requirements for crate preparation
• Inconsistent crate supply to packing lines
• Reduced packing line productivity during peak periods
• Increased manual handling risks for staff
The facility required a fully automated crate handling solution capable of delivering reliable, high-volume crate preparation while integrating seamlessly with existing packing operations.
The Solution
Fibre King designed and delivered an integrated crate handling system combining depalletising, crate erecting, and intelligent conveying technology.
Key Automation Components
The system includes:
RPC Depalletiser
Crate Stack Elevator
High-Level Crate Stack Conveying
Three GS RPC Crate Erectors
Manual tray input station with tray elevator
Integrated trunk line crate conveying system
The system architecture ensures a continuous and controlled flow of crates from pallet input through to packing line delivery.
Automated Depalletising for Continuous Supply
Pallets of collapsed RPC crates are loaded onto the system via forklift.
The automated depalletiser then:
Indexes the pallet into position
Secures the pallet and rotates it approximately 135°
Separates the wooden pallet from the RPC stacks
Transfers empty pallets to a pallet magazine
Stacks of RPCs are conveyed forward and orientated for feeding into the crate erecting machines.
The system can process up to 20 pallets per hour, ensuring a consistent supply of crates to downstream equipment.
High-Speed Automated Crate Erecting
The installation incorporates three Oryx GS RPC Erectors, designed to automatically open collapsed crates and deliver erected crates ready for packing operations.
Intelligent Crate Opening Technology
Stacks of RPCs are transferred into the erector magazine where the system:
• Separates individual crates from the stack
• Opens the long and short crate sides using pneumatic assemblies
• Locks the crate securely into its erected position
• Transfers the crate to the conveyor distribution system
Each erector operates at up to 20 crates per minute, while the trunk line conveyor is designed to support 30 crates per minute throughput across the system.
Crate size changeovers can be completed by a single operator in approximately five minutes, allowing the system to accommodate multiple crate formats.
Intelligent Automation and Control
The system is managed by an Allen Bradley PLC platform providing full automation, diagnostics, and operational monitoring.
Operators interact with the system via an intuitive HMI touchscreen interface which provides:
• Real-time machine status monitoring
• Diagnostics and fault reporting
• Operational control and configuration
• Multi-level operator access
Clear visual indicators allow operators to quickly identify system status:
🟢 Green – System running🟡 Yellow – Warning or startup sequence🔴 Red – Fault condition
The system also provides Ethernet connectivity for integration with broader plant automation systems.
Engineered for Reliability
The crate handling system incorporates a robust modular conveyor infrastructure designed for long-term reliability in demanding produce environments.
Key design features include:
• Modular belt transport conveyors
• Low back-pressure accumulation zones• Intralox modular belt technology
• Stainless steel and mild steel construction
This ensures smooth crate flow while preventing product congestion and maintaining consistent packing line supply.
Safety and Compliance
All equipment supplied by Fibre King complies with Australian Safety Standards (AS4024) and is designed under the company’s ISO9001 quality management system.
Safety features include:
• Fully interlocked safety guarding
• Positive locking access doors
• Automatic fault detection and shutdown systems
• Operator warning and alert systems
These safeguards ensure both operator safety and reliable machine performance.
Results & Operational Impact
The completed automation system provides the facility with a reliable and scalable crate handling platform designed to support high-volume fresh produce operations.
By automating crate preparation and handling, the system helps ensure packing lines receive a consistent and uninterrupted supply of erected crates, reducing operational bottlenecks and improving overall efficiency.
Operational Improvements
The automation system delivers several measurable benefits:
✔ Increased throughput
Automated depalletising and erecting ensure crates are continuously supplied to packing lines, supporting high production volumes.
✔ Reduced manual handling
Automation significantly reduces the labour required for crate preparation, improving workplace safety and operational efficiency.
✔ Improved packing line productivity
Consistent crate supply eliminates interruptions that can slow down packing operations.
✔ Reliable crate handling performance
Fibre King systems are engineered for durability and long-term reliability in demanding produce environments.
✔ Future-ready automation platform
The modular design allows the facility to expand or integrate additional automation as production requirements grow.
About Fibre King & Oryx Automation
Fibre King is a leading provider of automation systems for the food and beverage industry, specialising in end-of-line packaging and material handling solutions.
Since 2007, Fibre King’s Oryx Automation brand has focused specifically on crate handling automation, delivering durable and high-performance systems for growers, packhouses, and fresh produce suppliers around the world.
Oryx Automation solutions are engineered to deliver maximum uptime, operational efficiency, and long-term reliability in demanding agricultural environments.
Ready to Improve Your Crate Handling Operation?
If your packing facility is experiencing crate supply bottlenecks, high manual handling, or increasing production demands, Fibre King can help.
Our engineers work with growers and packhouses to design custom automation solutions that increase throughput, reduce labour requirements, and improve operational reliability.
👉 Speak with our automation specialists about your crate handling project today.
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