Home Chef Case Study:Fewer Pick Errors. More Room to Grow.
CHC and UNEX helped Home Chef improve picking accuracy, worker comfort, and flexibility with FlowCell modular flow racks and SpanTrack—supporting a busy operation preparing about 140,000 meal kits each week.
At Home Chef’s Maryland operation, associates prepare about 140,000 meal kits every week. Each meal bag contains 8 to 12 items, making accurate picking and smooth product flow essential to keeping orders on schedule.
With menus and customer preferences continually evolving, Home Chef needed pick lines that could adapt while making daily work more comfortable and efficient.
“Our business is always changing, and the FlowCell units allow us to adapt to variances and be ready for growth.”
Devin Chavis, Continuous Improvement Manager, Home Chef
The Operational Challenge
Home Chef’s plastic pipe-and-joint racks created recurring obstacles. Trays caught in the structures instead of moving smoothly, and cold conditions made the pipes brittle.
Each rack held only six pick items and could not be reconfigured. Home Chef needed room for 9 to 12 bins per rack, better access for associates, and a layout that could change with the menu.
Limited Storage Density
Existing racks restricted the number of ingredients available at each pick location.
Uncomfortable Reaching
Pick areas positioned too high or too low increased reaching and fatigue.
Inflexible Structures
Fixed rack configurations made it difficult to respond to changing meal requirements.
The CHC & UNEX Solution
CHC’s Daniel Cutler and UNEX’s Dan Teese toured the Baltimore facility and recommended replacing the existing racks with FlowCell and SpanTrack.
The modular flow racks improved storage density and product movement while giving Home Chef the flexibility to adjust pick locations. Following an initial trial, Home Chef ordered additional units and expanded their use to other facilities.
More Inventory in Reach
Compact flow racks hold more inventory while making better use of the available footprint.
A More Comfortable Pick
Adjustable heights and angled presentation bring ingredients closer to each associate.
Flexibility for New Menus
Modular configurations can be adapted as meal selections and operational needs change.
The Result: Accuracy, Speed & Space
Results reported at the Baltimore facility also included a 12% decrease in headcount associated with the more efficient picking environment. Inventory became better organized, properly stored, and easier to move through the operation.
Built Around the People Doing the Picking
The new racks can be raised or lowered to accommodate associate height, with parts angled toward the worker. Home Chef reported more comfortable picking, less reaching, and reduced fatigue.
Its maintenance team installed the units without disrupting the business, helping the operation keep pace with daily demand during the changeover.
Flexibility Beyond a Single Facility
Following the trial, Home Chef placed orders for facilities in San Bernardino, Atlanta, Chicago, and Baltimore. Each location prepares its own mix of meal kits, demonstrating the value of equipment configured around the needs of each operation.
The result is a picking environment that supports current demand while allowing teams to adapt to new food selections, dietary preferences, and future growth.
Inside the Home Chef Operation
Ready to Improve Your Picking Operation?
CHC works with UNEX to build efficient, ergonomic picking solutions around your products, people, and available space. Let’s explore a system that can adapt as your operation grows.
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