At Acme Corrugated Box, continuous improvement isn’t just a goal – it’s how we operate. Over the past several years, we’ve made a significant investment in modernizing our finished goods handling process, culminating in what we now call the “Acme Blue Route.”
This transformation represents a major step forward in efficiency, visibility, throughput, and most importantly, the safety of our people.
From Aging Infrastructure to Modern Flow
Like many facilities, our finished goods system once relied heavily on traditional roller conveyors. While reliable, it limited our ability to scale, automate, and optimize performance. There were also inherent safety concerns with having employees cross over the old conveyors.
In 2023, we began a multi-phase initiative to upgrade this system – replacing aging infrastructure with blue mesh conveyor and expanding automation across the line.
The safety difference was immediate. Blue mesh conveyor design significantly reduces accessible pinch points compared to traditional roller systems, and improved belt tracking means fewer product jams and less need for operators to intervene manually. Less intervention means less exposure – and that’s by design.
Expanding Capacity
The journey began with our main line extension, which expanded the finished goods conveyor into building 4, our newest building. This was a critical move to support increasing production demands.
By extending the line, we created the foundation needed for higher throughput and future growth. As part of this work, we also updated traffic flow plans to better separate forklift and pedestrian paths, and standardized conveyor crossing points throughout the space – building safety into the layout from the start.
Modernizing the Core Line
Next, we turned our attention to building 1, where a large portion of the existing roller conveyor was removed and replaced with blue mesh conveyor.
This upgrade improved:
- Product flow consistency – reducing jams and the manual interventions that come with them
- System reliability – fewer breakdowns means less maintenance exposure for our team
- Compatibility with automation – reducing human-system interaction at critical points in the line
It also marked a visible shift toward a more modern, streamlined operation.
Completing the Transformation
In late 2025 through early 2026, we completed the final stage of the conveyor upgrade – replacing the last remaining sections of roller conveyor on the main line.
At the same time, we expanded our unit tracking system, enabling real-time tracking and monitoring of finished goods without the need for fixed or handheld scanners. The design maintains clear line-of-sight and lighting throughout, so operators can monitor automated flow without having to move into the system to get eyes on product.
This enhancement provides:
- Greater visibility across the line
- Improved accuracy in product tracking
- Reduced manual intervention
With these changes in place, roller conveyor is now a thing of the past – and the system has officially become the “Acme Blue Route.”
Safety at the Center: What the Blue Route Really Means
Safety is Fundamental #1 at Acme Corrugated Box – and the Blue Route was designed with that in mind from day one. This isn’t just a conveyor upgrade. It’s a safety-driven redesign that reduces human exposure to mechanical, ergonomic, and material handling hazards at every stage of the line.
In practical terms:
- Designed to reduce employee exposure to moving equipment hazards – fewer pinch points, better belt tracking, standardized crossing points
- Minimizes manual intervention through engineered automation controls – the system handles more, so our people handle less
- Improves safety through real-time visibility and reduced human-system interaction – operators monitor the line, not wade through it
- Supports a proactive safety culture through system design – not just behavior – because the safest operation is one where the right outcome is built in, not just expected
That last point matters most. Behavior-based safety programs are important, but when you engineer the hazard out of the process, you create a safer more seamless workflow. The Blue Route does that.
What the “Blue Route” Means for Acme
The Acme Blue Route is more than a conveyor upgrade – it’s a smarter, more connected finished goods system.
It allows us to:
- Move product more efficiently
- Track inventory in real time
- Reduce manual touchpoints
- Support higher production volumes
Ultimately, it positions us to better serve our customers with faster, more reliable delivery.
What’s Next: Shipping Transformation in 2027
Our work isn’t done yet.
The final phase of this initiative is planned for early 2027, when we will overhaul how finished goods are processed in shipping. This will involve significant infrastructure and process changes designed to further increase throughput and get product out the door faster than ever.
Built for the Future – and for Our People
The Acme Blue Route is a clear example of how strategic investment and thoughtful engineering can transform operations. But more than anything, it’s proof that at Acme, the best operational decisions are also the safest ones.
As we continue to evolve, our commitment to enhancing performance, increasing efficiency, prioritizing employee safety, and delivering for our customers remains constant. .
Learn more about our capabilities!
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