U.S. Continental manufactures flexible packaging products used across food and consumer goods industries. The company operates production and warehouse facilities where materials frequently move between buildings as part of daily manufacturing and distribution workflows.
CHALLENGE
They needed a more efficient way to move more than one pallet at a time between buildings at its facility. Material transport relied heavily on forklifts making repeated trips across the campus, requiring significant labor time for a routine transport task. The company was looking for a safer, more efficient way to automate these repeat transport routes while improving overall operational efficiency.
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Tugger Usage Hours
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Labor Hours Freed
"Before adopting Cyngn’s autonomous tugger, we relied on a substantial manual effort, about 200 forklift trips per week to handle pallet deliveries between two buildings. Now, we move four pallets at a time, a 4x increase in efficiency, and our staff is freed up for more value added processes."
Dave Hoover
VP of Technical Services, U.S Continental
Deployment Summary
U.S. Continental, a manufacturer of flexible packaging products, deployed Cyngn’s DriveMod Tugger to automate pallet transport between buildings at its Wisconsin production facility. Previously, the operation relied on frequent forklift trips to move materials across the campus. The autonomous tugger now runs repeatable cross-facility routes, transporting multiple pallets per trip while operating both indoors and outdoors. Since deployment, the system has increased transport efficiency and reduced manual forklift movement.
Their Challenge
Coats is focused on running a low-cost, flexible manufacturing operation and is always looking for practical ways to improve speed, quality, and safety on the floor. Material delivery between production areas depended on manual tugger runs, with timing and routing varying from trip to trip and requiring frequent worker coordination. That inconsistency made planning harder and added unnecessary labor across routes with multiple stops and handoffs.
Key Challenges
Repetitive forklift trips required to move pallets between buildings Inefficient one-pallet-at-a-time material transport Labor time consumed by routine cross-facility delivery tasks
Our Approach
Cyngn worked with U.S. Continental to evaluate cross-facility transport routes and identify opportunities to automate repetitive forklift movements. The DriveMod Tugger was deployed to run fixed, repeatable routes between buildings while safely navigating both indoor and outdoor environments. Cyngn’s team tuned the autonomous system to ensure consistent operation and smooth integration into existing material handling workflows.
Our Solution
Cyngn deployed an autonomous DriveMod Tugger to automate cross-building pallet transport across the facility. The vehicle runs repeatable routes between buildings, hauling multiple pallets per trip while safely operating indoors and outdoors. By replacing frequent forklift trips with a predictable autonomous workflow, the system improves delivery consistency and reduces manual material handling requirements.
The Results
The autonomous tugger now handles routine pallet deliveries between buildings, significantly reducing forklift traffic across the campus. Because the vehicle can haul multiple pallets in a single run, material transport efficiency increased dramatically compared to manual forklift trips. With the repetitive transport work automated, warehouse personnel are now able to focus on higher-value tasks such as cycle counting, order picking, and inventory management while maintaining a steady, predictable material delivery rhythm across the facility.
Automated routine pallet deliveries between buildings Significant reduction in forklift traffic Material transport efficiency increased dramatically Employees are freed up to focus on higher-value tasks
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