Case Study: Vibratory Compaction Table Increases Gaylord Fill Efficiency for Frozen Broccoli

Situation

In a client’s frozen food packaging line, they fill large Gaylord totes with IQF (individually quick frozen) broccoli for bulk shipment. Prior to implementing vibration, the product would pile loosely in the tote, leaving voids and limiting how much material could be packed per unit.

Problem

Without vibration, broccoli settled unevenly and loosely inside the Gaylord totes. Despite careful filling, each tote reached its volumetric limit before reaching its maximum allowable weight. This inefficiency resulted in:

• Increased packaging material usage
• More frequent tote changes
• Higher freight costs per pound of product shipped

Solution

After speaking to our application experts, the client installed a stainless steel vibratory compaction table designed for sanitary, food-grade environments. As each Gaylord tote is placed on the table during filling, vibration is applied to gently settle and compact the frozen broccoli. The table is equipped with isolated vibration controls to ensure safe, uniform settling without damaging the product or the tote. This resulted in:

• A 20% increase in fill efficiency
• Consistent load density and product quality 
• Reduced labor and downtime

The client shared this positive feedback after installing the compaction table: “Since adding the compaction table, we’ve seen a clear improvement in how the product settles. We’re shipping fewer totes with more product in each, and we haven’t had a single case of damage to the broccoli.”