Improving Production Efficiency with Food-Grade Reusable Storage Systems
Australian Plant Proteins (APP) operates a state of the art processing facility in Horsham, Victoria, producing high-purity plant-based proteins for global food and beverage manufacturers. With rigorous hygiene standards and a strong focus on safety, sustainability, and product integrity, APP continually invests in equipment built for high-volume, high-reliability bulk handling.
As demand increased, APP introduced the UniBox; a purpose-built, food-grade reusable storage and transport system designed to reduce contamination risk, eliminate waste, and improve material flow. By transitioning from single-use bulk bags to the UniBox system, APP cut waste, enhanced operator safety, and strengthened production efficiency across their large-scale handling operations.
Business: Australian Plant Proteins (APP)
Industry: Plant Protein Extraction & Processing Facility
Location: Horsham, Victoria
Product: Unibox
The Challenge
With demand for plant-based proteins accelerating, APP needed to scale production without compromising product integrity, worker safety, or operational efficiency. However, their existing handling system was creating unnecessary waste, production delays, and avoidable risks.
Key Issues:
- Heavy, single-use bulk bags that were inefficient, hard to handle, and prone to wear and tear
- Frequent spillage and contamination risks during filling, transport, and storage
- Tearing and product loss that disrupted workflow and increased waste
- Slow unloading times with each bulk bag taking around 17 minutes to empty into processing hoppers
The Solution
To address these inefficiencies and strengthen product integrity, APP partnered with United Ag to implement the UniBox, a robust, food-grade reusable storage and transport system engineered specifically for flowable materials used in food manufacturing. Replacing single-use bulk bags with the UniBox delivered immediate operational gains, significantly improving hygiene control, handling efficiency, and overall processing reliability.
Key Advantages:
- High-durability containers designed to withstand continuous industrial use without tearing, sagging, or structural fatigue
- Accelerated, contamination-free unloading made possible by the UniBox’s smooth internal surfaces and high-flow outlet geometry
- Enhanced product protection through sealed, food-safe lids that prevent moisture ingress, airborne contaminants, and material exposure
-
Safer, streamlined one-person handling that reduces manual intervention, forklift movements, and operator risk
The Result
Integrating the UniBox system delivered immediate, quantifiable improvements across APP’s Horsham facility, strengthening production efficiency, product protection, and worker safety. The shift from single-use bulk bags to a fully reusable UniBox system has transformed how raw materials move through the plant.
- 50% faster unloading times, each UniBox empties a tonne of faba beans in just 8 minutes , down from 17
- $250,000 in annual operational savings driven by reduced labour, downtime, and product loss
- Tripled storage efficiency - the same footprint now holds three tonnes of product instead of one
- Improved handling safety with greater forklift stability and reduced manual lifting and bag handling
- Stronger product integrity through sealed, food-grade containers that minimise exposure and contamination risk
Puneet Chawla, Operations Manager
“You could say it ticks all the boxes for us. We’ve been using United Ag’s UniBox at our Horsham facility for several months now, and the improvements were immediate.”
By integrating the UniBox system, APP has strengthened its position as a leader in safe, efficient, and sustainable plant protein manufacturing. The Horsham facility now benefits from a streamlined, reusable material-handling process that reduces waste, enhances product protection, and supports APP’s long-term commitment to responsible, future-focused production. These improvements not only increase operational reliability but also align with APP’s broader goal of building a cleaner, more sustainable supply chain for the plant-based ingredients sector.
Phil McFarlane, Director
"With UniBox we can store 3 tonnes of product in the space that we used to store one tonne. But the real game-changer is the dispensing; what used to take 30 minutes with two people climbing on equipment, now takes 30 seconds with one person safely on the ground."
United Ag is proud to partner with Australian Plant Proteins on their journey toward safer, smarter, and more sustainable operations.
A special thank you to Puneet Chawla and Phil McFarlane, for sharing your valuable insights.
Published: 17 March 2020
Looking to optimise your bulk material handling and streamline operational flow? Explore the UniBox™ engineered solutions here:
Unibox