Discover how CopperState Farms transitioned from manual packing to fully automated container packaging increasing throughput, reducing labor, and maintaining consistent product quality across multiple retail locations with LeafyPack’s RotoBagger Award Winning System
CopperState Farms is a vertically integrated operator, managing everything from propagation to extraction and packaging. With over 44 acres of greenhouse operations producing thousands of plants daily, their manual container packaging process became a major bottleneck.
Previously, a team of 5–6 operators could only handpack about 2,000 units per day, which was insufficient to meet the needs of their nine retail locations and additional dispensary clients across the state.
Challenges included:
The team needed a solution that could:
LeafyPack implemented an integrated automated system using the RotoBagger for high-speed bagging and the Apollo Pro for precise product handling.
Automated Precision Packaging
The Apollo Pro ensures accurate, repeatable fills, removing reliance on manual counting.
High-Speed Bagging
The RotoBagger significantly increased throughput, enabling CopperState Farms to meet growing demand.
Labor Optimization
Employees previously dedicated to repetitive manual tasks were redeployed to higher-value production areas.
Operational Efficiency
Automation reduced bottlenecks, improved workflow, and allowed for better forecasting and inventory control across multiple retail locations.
Reliable Support
LeafyPack provided hands-on installation, training, and ongoing support, ensuring a seamless transition and minimal downtime.
“Pre-automation, there was no way we could supply all nine stores without tripling our facility. With LeafyPack, we’re packaging 5–6,000 units a day with minimal downtime, consistent product quality, and enough capacity to get ahead of our forecast.”
LeafyPack collaborated with CopperState Farms to customize the system for their operations. Installation was efficient, minimizing disruption to daily production.
Operators quickly adapted to the workflow thanks to the intuitive system design, and the facility saw immediate improvements in speed, throughput, and quality control. The automation also allowed for smoother handling of multiple product lines and genetics, supporting both current demand and future growth.
2–3× Increase in Output
Daily packaging scaled from ~2,000 units to 5,000–6,000 units.
Eliminated Manual Bottlenecks
Hand packing was fully replaced, removing one of the most time-consuming steps.
Improved Labor Efficiency
Staff previously dedicated to counting were reassigned to other areas, optimizing workforce deployment.
Consistent, High-Quality Packaging
Precision automation ensured uniform fills across all containers, preserving product integrity.
Scalable Operations
The system positioned CopperState Farms for future growth and expansion across retail locations.
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