Integrity Machine System Drives Efficiency in Stacking and De-Stacking

In the world of manufacturing and warehouse operations, material handling is often seen as a routine function yet it’s one of the most critical links in the supply chain. As manufacturers increasingly adopt lean principles and Just-in-Time (JIT) delivery models, the limitations of manual stacking and de-stacking processes are becoming impossible to ignore.

Manual handling of materials particularly heavy totes, boards, or pallets can lead to: injury, inconsistent workflows, labor shortages, and increased operational costs. These issues are common in facilities still reliant on outdated practices. The need for safer, smarter, and more flexible solutions is urgent.

That’s where Integrity Machine Systems (IMS) is making a powerful impact. In partnership with Precision Tools Service (PTS)—an Omron Automation strategic partner—IMS is pushing the boundaries of what’s possible in automated stacking and de-stacking. Their customized solutions are transforming material handling workflows across industries, providing a compelling blueprint for flexible, safe, and scalable automation.

The Hidden Costs of Manual Stacking

While often overlooked, stacking and de-stacking are fundamental steps that affect material flow, production uptime, and workforce safety. In a typical operation, employees must repetitively lift, align, and move heavy items, often in confined or fast-paced environments. These repetitive motions contribute to ergonomic injuries, high turnover, and reduced efficiency.

“Many of our customers were struggling with outdated, manual systems that simply couldn’t keep pace with modern production demands,” says Frankie Spellman, Vice President of Integrity Machine Systems. “The labor was intensive, the errors were frequent, and the safety risks were escalating.”

As global supply chains become more interconnected, any inefficiency in upstream handling can trigger downstream disruptions. For manufacturers adopting JIT strategies, even small delays in stacking can halt entire production lines.

Why Automation

The needs for automating stacking and de-stacking is clear: increased speed, reduced labor dependency, and better workplace safety. But the real breakthrough comes when automation is not just applied but intelligently integrated.

IMS’s fully automated stacker and de-stacker solution is designed to do just that. At the heart of the system is Omron Sysmac automation platform, which uses high-speed EtherCAT® communication to deliver precise, real-time control. This enables the system to manage diverse load sizes and materials with speed, accuracy, and consistency.

The solution is flexible to accommodate different tote, board, and pallet configurations, making it ideal for mixed-product environments. Whether deployed in consumer packaged goods, automotive, or general manufacturing, IMS’s system ensures that the right materials are always in the right place without putting workers at risk.

How It Works

Instead of relying on manual labor, IMS’s system automates the stacking and de-stacking process by organizing materials into compact, stackable units. This not only optimizes storage and floor space but also streamlines material flow.

The real-time data visibility provided by the Sysmac platform enables operators to monitor performance, adjust parameters, and respond to issues before they cause downtime. And with fewer human touchpoints, the solution significantly reduces contamination risks, an important factor for industries with strict quality control requirements.

Maintenance is also streamlined. “System startups are quicker, and service demands are reduced thanks to the modular, smart design,” explains Frankie Spellman, Vice President at Integrity Machine Systems. “This allows manufacturers to operate at peak performance without getting bogged down by troubleshooting or downtime.”

Delivering Measurable Business Results

The benefits of the IMS system go far beyond technical performance. Manufacturers can benefit by leveraging this automated solution:

• Improved labor efficiency: Reduced reliance on skilled operators for repetitive tasks frees up human capital for higher-value work.
• Lower ergonomic risks: Automation eliminates the repetitive motions that commonly cause workplace injuries, improving employee well-being and retention.
• Enhanced throughput: Reliable and consistent stacking accelerates material movement into and out of production lines.
• Better support for JIT delivery: With smoother material handling, operations can better meet time-sensitive delivery targets and customer expectations.

Next-Level Mobility

IMS is not stopping at stationary systems. Looking ahead, the company is planning to integrate Omron’s Autonomous Mobile Robots (AMRs) into its solutions, enabling dynamic and responsive material transport within facilities.

“By combining high-speed stacking automation with mobile robotics, we can take material handling efficiency to a whole new level,” says Frankie Spellman, Vice President of Integrity Machine Systems. “We envision fully connected workflows—from raw material receipt to finished goods shipping—that are intelligent, agile, and nearly hands-free.”

Such advancements point to a future where human labor is reserved for creativity, decision-making, and innovation—while automation handles the heavy lifting.