Kainui Pack & Cool Improves Safety and Efficiency with a Smarter Loading Process

For packhouses, loading is one of the most physically demanding parts of the operation.

It’s where product leaves the cool store, deadlines become tight, and teams work at pace to keep containers moving. When the loading process isn’t working as efficiently as it could, the impacts are felt across productivity, labour requirements, and health and safety.

For Kainui Pack & Cool in Kerikeri, the team recognised an opportunity to improve how containers were loaded. They wanted a safer, more efficient process that would better support their people and their growing export operation.

 

The Challenge

Before the upgrade, loading containers involved a significant amount of manual handling.

According to Kainui’s Production Manager, the process was both slow and potentially hazardous for staff.

“It was slow and dangerous.”

Operators were required to manually move pallets inside containers and climb onto trailers to gain access. Working around tyres, chassis rails, and uneven surfaces introduced unnecessary risk while also slowing down the loading process.

In a busy export environment handling kiwifruit, lemons, and citrus, these inefficiencies can quickly add up, particularly during peak season when throughput becomes critical.

The team knew there was a better way.

 

A Clear Goal

Kainui’s requirements were straightforward.

They wanted a loading system that would allow work to be managed from inside the cool store while improving safety for operators and reducing the physical demands of the job.

Most importantly, they wanted safe, reliable access into containers without requiring staff to climb onto trucks or work in unstable positions.

As the team explained:

“I needed to be able to do everything from inside the cool store”

A Better Way Forward

The upgraded loading setup introduced a more structured process for accessing and loading containers.

Operators can now safely access the trailer via a dedicated platform before forklifts move product into the container through a secondary ramp system. The process is more controlled, more predictable, and easier to manage throughout the loading cycle.

Rather than relying on workarounds or physically demanding manual methods, the team now works within a system designed specifically around the way the site operates.

 

The Results

Safety Improvements

For Kainui, safety was the primary driver behind the project.

The previous process required staff to climb over parts of the trailer to gain container access, creating an obvious risk of slips, trips, and falls.

The new setup has significantly improved how operators access containers, providing a safer and mor stable working environment.

As the production manager put it:

“Just safety… that’s solely the reason that I wanted a way to access the container that was safe.”

Faster Loading Times

The safety benefits have been matched by substantial operational gains.

During busy periods, Kainui can now load up to three containers per hour, with loading times reduced to approximately 20 minutes per container.

The improved workflow enables product to move more efficiently from cool store to container, helping the team maintain throughput during peak export periods.

Reduced Physical Strain

The upgrade has also reduced the level of manual handling required throughout the loading process.

By creating a more streamlined workflow, staff spend less time performing physically demanding tasks and more time focused on efficiently moving product.

This has helped reduced fatigue while improving the overall loading experience for operators.

Greater Operational Consistency

Beyond the measurable improvements in safety and speed, the new system has created a more consistent loading process.

With a clear workflow in place, loading can be carried out the same way each time, making operations easier to manage and providing greater confidence during busy periods.

Summing up the impact of the project, the Kainui team said:

“Efficiency and safety… that’s what it’s improved.”

 

Supporting a Growing Export Operation

For Kainui Pack & Cool, the project was ultimately about making a critical part of the operation work better.

By improving container access, reducing risk, and streamlining product flow from the cool store to the container, the team has achieved meaningful improvements in both safety and efficiency.

The result is a loading process that better supports staff, improves throughput, and helps the business continue meeting the demands of a busy export environment.

 

Looking Ahead

For Kainui Pack & Cool, this upgrade wasn’t about complexity – it was about practicality.

By focusing on how the site actually operates, the solution delivered measurable improvements in safety, efficiency, and usability.

It’s a strong example of how a well-designed loading system can support the entire operation – from the cool store through to dispatch.

 

Talk to Ulti Group

If you’re reviewing your loading process or planning an upgrade, we can help you design something that works for your site.

👉 Talk to our team about packhouse and export loading solutions

👉 Or get in touch to review your current setup