Fiduciary Carton Tracking in Processing Facilities without an Automated Storage and Retrieval System (ASRS)

JBS and other Australian processors face challenges efficiently tracking Frozen and Chilled meat cartons through cold stores. When cartons are placed on pallets (or part pallets) and stacked many layers deep and high in a cold store, it then becomes difficult for cold store staff to find the correct cartons to fulfil a shipment order. This scenario creates challenges to fulfill orders in full and in a timely manner, fulfill orders with aging stock being prioritised over newer stock, and eliminating out of date stock. Ideally these challenges can largely be overcome with the deployment of Automated Storage and Retrieval Systems (ASRS). Unfortunately, these systems have a high capital cost ($25-100M depending on capacity) and it is just not feasible to deploy ASRS systems throughout the industry in all situations due to available space and the high capital cost. As a low-cost alternative to the tracking capability an ASRS system offers for carton tracking, this project proposes a PoC deployment of a reflective QR code system, with QR codes applied to cartons. These cartons will be tracked within the cold storage facility as they are placed into racks. Tracking will be facilitated through additional fiduciary markers in the cold storage facility and a "smart vision" system mounted on forklifts. Successful validation of this PoC will form a robust foundation for further development. This PoC project serves as one component of a comprehensive system solution and its outcomes will lay a strong foundation for the development of an end-to-end carton tracking system. The goal is to improve the efficiency of locating and retrieving cartons in cold storage facilities to ensure timely and accurate order fulfillment. It is designed to address key operational priorities, such as adhering to shipment requirements, selecting the oldest stock first and complying with export shelf-life regulations while managing the challenges of large-scale operations. If successful and after further development this solution will offer a viable low-cost carton tracking solution for any size processing facility.