Scan-Free Warehouse Logistics at JACO Grinding USA
Digital container cycle delivers 15% more profitability and 99% less search time
JACO Grinding is a U.S.-based company specializing in stone processing. At two production sites in North Tonawanda, NY, materials are refined in multiple stages – from coarse to fine grinding. Internally, material flow is handled almost entirely via containers.
With growing production demands and increasing complexity, the company reached the limits of its existing warehouse logistics system.
Initial Situation & Challenges
Before implementing the IdentPro solution, JACO Grinding faced several pressing issues:
Objectives
The goal was to implement a system that would:
Project Execution During the Pandemic
The project began during the height of the COVID-19 pandemic and was carried out entirely remotely during the first three phases. Weekly video calls ensured close collaboration between the two teams to analyze processes, define goals, and clarify technical details. One aspect that stood out was IdentPro’s methodological depth: “IdentPro’s questions led us to understand our own operations on a whole new level,” says Al Bluemle, CEO of JACO.
Despite travel restrictions, the technical setup went smoothly. JACO installed the necessary hardware on the forklifts independently on-site guided by clear instructions and daily coordination with the IdentPro team. Once travel restrictions were lifted, the go-live was supported by a three-week on-site training session. All relevant employees were trained, and the system went live without issue.
The Solution: Digital Container Cycle with RTLS
Refilling the containers
At the heart of the implementation is the digital container cycle, enabled by the IdentPro Warehouse Execution System (WES). Each container is uniquely identified and permanently registered in the system using a fixed ID. Material, weight, and fill level are recorded automatically, eliminating the need for manual input. The location of each container is tracked in real time using a Real-Time Location System (RTLS), even in dynamic environments with frequent movement and change.
One of the most effective elements was the seamless integration with JACO’s existing batching system, which significantly reduced operator errors on the production line. The solution is further enhanced by the use of digital twins: each container is represented in the system as a complete digital model – with its current location, status, and contents always up to date.
Status and content include not only fill level (e.g., full or empty), but also detailed information such as article number, associated production order, or material weight. Thanks to geofencing-based zone transitions – at cleaning, inspection, or shipping stations – the status of each container is automatically updated. For example, when an empty container is placed in a cleaning zone, its status changes automatically to “cleaned” in the system. This allows for targeted queries at any time, such as: “Show me all cleaned empty containers.”
Today, JACO benefits from a fully transparent and always up-to-date digital inventory of all full and empty containers.
Results & Business Impact
Implementing the IdentPro system proved to be a game-changer for JACO:
Scan-Free, Paperless Warehouse Logistics – From container to machine, IdentPro’s solution provides full transparency, reduces errors, and delivers measurable efficiency gains.
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