KEYENCE BT-A Series Handheld Mobile Computers Help Fast-Growing Wholesale Food Distributor Improve Warehouse Accuracy and Efficiency
As food distributors expand their operations, maintaining accurate inventory while increasing throughput becomes ever more important. For California-based Gemini Food Corporation, integrating KEYENCE BT-A Series handheld mobile computers with its HighJump warehouse management system (WMS) has streamlined processes and improved picking accuracy, providing the reliability needed to support continued business growth.
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Headquartered in City of Industry, California, Gemini Food imports and distributes Asian food products to over 1,000 customers, including the largest U.S. based Asian supermarket chain and a national household-name wholesaler. With clients of this stature, the company relies on efficient warehouse operations to ensure orders are fulfilled correctly and on time.
"We're currently on a rapid growth trajectory,” reports Alexander Chiu, Business Systems Analyst at Gemini Food. “The organization is considerably bigger than it was even just a couple of years ago. Notably, we're starting to win business from big-brand customers, so maintaining our excellent order picking precision and efficiency is more important than ever."
Better fit for warehouse operations
Chiu oversees the company's warehouse IT infrastructure, including its WMS and ERP (enterprise resource planning) software integration, barcode scanning technology, and wireless networking. When he joined Gemini Food a few years ago, he realized that the company's existing handheld scanners were hindering warehouse productivity.
"We were using big, bulky barcode scanners and the range wasn't great," he explains. "Our warehouse staff are constantly moving around while picking orders, and don’t want to be carrying a giant scanner. We looked at several alternatives, but many were not that different to what we already had."
During the evaluation period, Gemini Food noted a standout contender: the KEYENCE BT-A Series handheld mobile computer.
"We were impressed by the compact size, light weight and scanning range. We tested the devices thoroughly and our warehouse operatives were impressed.”
Today, the company operates multiple BT-A Series handheld computers across its three facilities, all of which are in California.
Straightforward WMS integration
Gemini Food has been using HighJump WMS, which rebranded to Infios in 2025, for around eight years. One of the advantages of moving to the KEYENCE devices was the simplicity of deployment.
"The handheld part of Infios is browser based," explains Chiu. "As long as the scanner has a web browser, it works. We could therefore hit the ground running when we switched to the KEYENCE BT-A Series devices. It was so easy.”
The handheld computers are used across Gemini Food’s three facilities to scan barcodes on incoming food cases, confirm put-away locations, support picking activities, and validate outbound shipments.
The scanners communicate directly with the Infios WMS to validate every warehouse transaction. Operators scan locations to confirm the correct bin for the food case, and if they scan the wrong item, the WMS sends an immediate alert. Every scan updates inventory in real time, which keeps stock records accurate and makes cycle counting much more efficient.
Improving warehouse accuracy
While Gemini Food tracks numerous warehouse KPIs, Chiu says accuracy remains the company's primary performance measure: "We've seen a notable improvement in accuracy with the KEYENCE scanners, largely because they're able to scan from much further away.”
The extended scanning range has eliminated a common source of error.
"Our upper storage locations are around 30 ft (10 m) high. Previously, operators couldn't scan those barcodes, requiring manual entry of the barcode numbers. Inevitably, this activity occasionally introduced human error. With BT-A Series scanners, we can scan those locations directly, improving accuracy."
Chiu also highlights the ability of the KEYENCE handheld mobile computers to capture difficult barcodes reliably: "They're able to scan pretty much every barcode, even labels that aren't in the best condition."
Supporting continued growth
Three to four years after deployment, the BT-A Series handheld computers continue to perform reliably across Gemini Food's warehouse operations.
"They've definitely met our expectations," says Chiu. "The devices are so reliable that we've rarely needed to contact KEYENCE, but on the few occasions I needed advice, they've been very responsive."
Looking ahead, Gemini Food expects innovative technology to remain central to its expansion plans as the business continues to grow.
"Investing in the latest technology is so important because it helps us maximize efficiency and quality, not only for our own business but also for our customers," he concludes. "Our customers expect correct orders delivered on time.”
HighJump warehouse management system (WMS) menus displayed on the KEYENCE BT-A Series.
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