Qingyuan Beverages — a well-known beverage producer in East China.
The plant outputs tens of thousands of bottles per day, with more than 15,000 pallet cycles daily.

1. Project Background

Qingyuan runs 24/7 continuous production with high-turnover warehousing. As orders kept climbing, outdated wooden pallets increasingly caused safety, hygiene and cost issues, threatening line stability and GMP audit scores.

2. Challenges

Wood-chip contamination
Typical symptom: splinters from wooden pallets drift into the filling line and trigger shutdowns.
Business impact: unplanned downtime exceeded 4 h per month.

Moisture & mold
Typical symptom: pallets absorb water, mold and exceed hygiene limits.
Business impact: repeated GMP deductions; extra sanitation required.

Structural failure
Typical symptom: pallet breakage or warping leads to product tipping.
Business impact: scrap rate ≈ 30 %; rising loss and claims.

Manual burden
Typical symptom: water-soaked pallets become heavier, increasing handling effort.
Business impact: higher injury risk and overtime costs.

3. Solution

Upgrade to Baoheng food-grade PP plastic pallets
One-piece injection-moulded pallets with smooth, burr-free surfaces and anti-slip grid. FDA-grade PP allows high-pressure wash-down and resists deformation under 1.6 t static load from -35 °C to +60 °C.

Minor layout tweaks
Rack locations were re-marked to fit the new pallet size, and drip-dry racks were added in the wash area to speed turnaround.

4. Results (within 3 weeks of go-live)

Wood-chip contamination
Before: 5–6 unexpected shutdowns per week.
After: fully eliminated; shutdowns 0.

GMP deductions
Before: 2–3 penalty points per spot-check.
After: 0 points; hygiene risk cleared.

Pallet breakage rate
Before: ≈ 30 %; high repair spend.
After: < 1 %; almost no repair cost.

Manual burden
Before: high strain on forklift staff; injury & overtime risk.
After: handling effort down ≈ 33 %; injuries and overtime drop sharply.

Annual savings
Optimising downtime, scrap and labour is projected to save ≈ ¥650,000 per year.

5. Client Testimonial

“Wooden pallets used to give us headaches: contamination fines, midnight repairs, breakage claims… problems never stopped.
Now the plastic pallets are clean and durable; the three-shift line no longer pauses, and we save over ¥600 k a year on repair and scrap alone.
Most importantly — peace of mind.”
— Wang Haibo · Logistics & Warehouse Manager, Qingyuan Beverages