Conveyor systems are versatile machines, working in tandem with a variety of material handling solutions, ensuring increase output and productivity. Besides the additions of machines in conjunction with a conveyance solution, there exists extended automation for the conveyor system itself.
Belting plays a critical role in how the product moves throughout the system, but typically, most operations use either a roller conveyor or a flat belt. What many do not realize is that belting can be upgraded to automatically position cartons in a way that simplifies various induction steps in the line.
ARB (Activated Roller Belt) technology revolutionizes the way a conveyor system functions by offering automatic aligning and positioning, precise gapping, high-speed sortation and diversion, uniform operator station package distribution, and more.
ARB equipment performs a variety of different functions on the product by utilizing free-spinning rollers that are embedded in plastic belt modules. The rollers can bi-directionally manipulate products in a variety of different angles and trajectories. The rollers can be bi-directional or omnidirectional depending on the usage of that specific belt space. The rollers reorientate themselves rapidly depending on the destination of the package.
ARB equipment can provide substantial throughput benefits while providing a quick return on investment by eliminating time-consuming manual labor and being flexible enough of a solution to apply to a variety of operations.
Infeeding and Outfeeding
1. Sortation Systems
Bi-directional right-angle sortation that activates the belt rollers when the carton reaches its divert destination. This form of sortation is high speed, with rates up to 250 packages a minute, in a compact footprint. If your facility distributes a variety of packages, this sortation method can accommodate polybags, crates, top-heavy items, and more, along with typical flat-bottomed cartons.
In facilities where a continuous flow of a mix of bulk packages is present, ARB equipment can be employed to sort an even volume of packages for downstream processing (operator stations, for example). Due to the bulk nature of the continuous induction, sortation rates can achieve up to 360 packages per minute, automatically avoiding jams.
2. Depalletizing Systems
Depalletizing can be a laborious operation if done manually. With ARB equipment in use, omnidirectional track rollers can descramble up to 6 pallet layers per minute and place them in a uniform line, ideal for scanning or picking. By alternating packages left and right on the ARB conveyor, and using the side railing as a guide, packages line up neatly for downstream applications.
Singulating, in this context, means to place the items in a single, congruent line. Depending on induction rates, this could be a continuous line, or broken up into segments (for example, one segment having four packages). ARB equipment moves the undistributed packages from left to right to acquire a straight line, using the railing of the support to gently align the items. This eliminates the need for manual clearing of side-by-sides, recirculation due to miss-sorts, and enables workers to place items on without concern for positioning.
In a polybag-focused operation, reliable merging from multiple infeeds is paramount to downstream processes. ARB conveyor solutions merges infeed conveyors with a high-speed directional belt, while maintaining gapping, and alignment, for later scanning and sortation operations. All of this is completed in a relatively small footprint, as an ARB conveyor is designed to quickly merge the lanes.
Polybag destination switching
If lanes are not merging, but instead, crossing polybags over each other to their reach their destination lane, an ARB conveyor solution can achieve this efficiently. Much like the merging ARB conveyor, omnidirectional rollers quickly switch polybags into their respective destination outfeeds, while maintaining proper gapping and alignment.
6. Zone Picking
Pick and pass order fulfillment zones can also benefit from ARB equipment inclusion. Manual picking stations can be added to a central conveyor merge, utilizing an omnidirectional sorter to easily pick packages from the main line to be processed, and then re-introduced back to that same conveyor. Order fulfillment can be completed at rates greater than 25 packages per minute, and only needs one 24-volt motor to drive the rollers.
7. Infeeding and Outfeeding
Used in conjunction with an automatic storage and retrieval system (AS/RS), this ARB conveyor combines both infeeding and outfeeding operations. Packages can both be sent to storage, while simultaneously accepting packages coming from storage. This is achieved by utilizing omnidirectional sorters in conjunction with right angle diverters, with alternating flow directions that activate depending on the carton’s destination. Sortation can achieve excess of 30 packages per minute, while infeed/outfeed rates to an AS/RS can reach 1,800 cases or totes per hour.
Intralox equipment has been successfully implemented by retail, grocery, manufacturing, and direct-to-consumer e-commerce distribution centers. The technology brings value in many applications ranging from high-speed 90-degree sorting to AS/RS infeeding and outfeeding. From increased throughput to flexible package handling and efficiency, Intralox’s conveyance technologies pick up where traditional technologies end.
Century is a longtime partner and integrator of Intralox, utilizing its innovative ARB equipment technologies throughout a wide range of clients. Together, a truly efficient system can be designed, engineered, and installed to increase output, accuracy, and ROI.
How automation solutions fulfill today’s parcel shipping demands
Parcel delivery expectations have increased exponentially, exacerbated by the effects on consumers of the pandemic, and the movement of large E-commerce players offering 1-day or even same-day shipping. Consumers expect quick shipping in comparison to a decade ago when a speedy delivery was a premium option.
In a recent report by McKinsey & Co., online product categories have experienced a 15% to 40% increase in user growth during 2020. That increase of users means higher expectations for faster shipping speeds, and in turn, carriers and shippers will be expected to offer and fulfill such services.
To accommodate the demand, automation has been utilized to rapidly speed up processing and sortation operations. Forgoing manual labor opens the door to quick shipment offerings, a tantalizing benefit to any prospective client. Automated solutions typically depend on the conveyor and divert systems, which need to be versatile enough to handle small parcels like letters and polybags, to larger carton packages. Belt conveyors are used, versus roller, as smaller items could get stuck in between rollers if the weight is undistributed across incorrectly. Where automation differs, is in its sortation method:
Tilt-tray sortation uses order consolidation chutes to sort items in a batch-pick environment. Cartons are scanned before being inducted onto a tilt-tray carousel, where it will sit on a moving platform until it reaches its destination chute. The tray will tilt either left or right depending on where it’s being sorted and slide down a chute onto a conveyor to be loaded.
Tilt-tray applications are effective for high-speed sortation.
Functioning similar to the tilt-tray, cross-belt sortation differs by using bi-directional belts to divert items into destination chutes. Packages are inducted onto the cross-belt conveyor carousel and sorted accordingly. Each belt section can hold one package, but multiple belt sections can be combined and used in tandem to divert larger items.
A series of narrow belts, each with its own take-up, span the length of the conveyor. High friction divert wheels rise between the belts, diverting product to its destination.
Narrow belts are typically used for larger, heavier packages that need heavy-duty forms of sortation. Smaller packages would not be ideal for this application, as they would fall in-between the belting segments.
High-speed sorter utilizing aluminum slats that have plastic shoes that slide across them to divert cartons either left or right (bi-directional) to required sort destinations.
The advantage this provides over the similar functions of the tilt-tray is that the shoe is incorporated as part of the central induction conveyor. This eliminates the need for a separate sortation application, like the aforementioned tilt-tray carousel.
Sometimes also referred to as a bomb-bay sorter, dual split tray sorters have the ability to sort two smaller items within the same tray, at higher throughput speeds.
Split-tray sections have a bottom platform that opens to drop items gently into chutes, totes, or cartons below. This method is space-saving, as the item discharge area drops below vs being conveyed.
Swivel Wheel Sorter
Swivel wheel sorters utilize a platform of omni-directional rollers to divert items quickly. When a product reaches the divert, the wheels orientate to direct the item to its destination. This sortation method works best for systems that have a conveyor junction, rather than a gradual merge or curve.
A high-speed sorter with tray segments utilizing a positive divert to gently push items or polybags off the tray and slide them into a sortation chute.
Depending on the dimensions of the parcel processed, each conveyor sortation method varies slightly, and one solution may work better than another one. It’s a function of careful engineering and planning to discover which one would work best. Regardless, any conveyor sorter will far exceed manual labor.
Parcel Customer Expectation
Mainly attributed to the increase in e-commerce usage, the courier, express, and parcel (CEP) market is expected to exhibit a CAGR of over 6% from 2021-2026 (source). To adjust to this substantial demand increase, automation and technology are taking center stage to provide future solutions. Parcel distributors have their work cut out for them, as operations need to accommodate for the increase, as well as deliver to customers within 1-2 days.
ShipStation’s report “Last Touch, Lasting Impact” highlighted insightful statistics in how consumers view various topics concerning shipping. A few pertaining to parcel shipping expectations include:
86% say a poor shipping experience negatively impacts their perception of the retailer.
87% say that shipping and delivery experience directly impacts their decision to shop with the merchant again.
47% of customers are more likely to pay for express shipping now than they were pre-COVID.
Clients strive to uphold the best delivery experience for their customers, and that expectation extends to their parcel handling partner. Recurring slow shipping speeds and errors in sortation can spur negative consumer sentiment or increase returns, something clients work very hard to avoid.
The parcel industry is a constantly evolving sector, as automation technology continues to provide solutions for quick handling and delivery of packages. The post-COVID explosion of online shopping has led many forward-thinking parcel shippers to evaluate their current operations and develop an integration plan.
Century Systems understands how critical effective parcel operations are to maintain customer delivery satisfaction. Our primary focus is to engineer an automated solution that provides a profitable output and is curated specifically to your warehouse layout.
Conveyor system downtime is a constant threat to a continuously profitable operation. The importance of proper maintenance and ongoing support is paramount to keeping orders shipping on time and clients satisfied. Unplanned downtime can cost companies up to $250,000 per hour, with 82% of businesses experiencing at least one system outage over the past three years (source).
How do you avoid those monumental losses? Here are a few options your business can take to proactively prepare against downtime.
Preventative Maintenance Service Plans
Hotline Support Agreements
On-site Repair Services
Spare Parts Inventory Management Programs
System Retrofits & Modernizations
1. Preventative Maintenance Service Plan
Some systems run 24/7 and are vital to keeping your operations effective. With hundreds of moving parts and sometimes a complex controls network, it is inevitable something will need to be replaced or repaired, often at the worst possible time.
Avoid the costs and frustrations of downtime and schedule a system audit followed by a comprehensive quarterly, or bi-yearly preventive maintenance program.
A team of experienced certified technicians will walk through your system validating each unit/component, age and condition, available working hours, and more during the initial audit. An optimized Preventative Maintenance plan and associated cost will then be developed for review and implementation.
2. Hotline Live Support (24/7)
Certain integrators may offer live digital support, to guide your designated controls engineer to a solution. This can be achieved by using a VPN to remotely control your system, allowing the support agent to view all error codes, make corrections, and guide your team accordingly.
For example, if an emergency stop cord is pulled, it is a relatively easy fix via the control system, but only if your controller can identify the issue. Instead of sending out a maintenance team, a support agent can remotely clear the codes and restore the system quickly.
When contracting with an integrator, ensure that they have this service as part of the proposal. Century includes a year of hotline support with every solution purchase, as well as multi-tiered options depending on the complexity.
3. On-call Emergency Repair
System downtime can occur due to factors often outside the control of normal operations. Life cycle wear, operator errors, power fluctuations, etc. cannot be predicted from an occurrence perspective. Even with an internal maintenance team, a specialist may be needed to address and remedy the situation.
Century can dispatch a team of certified technicians to your location in 24-48 hours and when layered with a Hotline Support Agreement, may even be able to resolve the problem within hours.
Our emergency repair service is within a call away as a safety net in the event of a system failure.
4. Spare Parts Optimization Programs
Downtime is typically the issue of a single component failing, bringing operations to a stop. Like a chain, if one link is broken, nothing works. Now you are scrambling to order a new part from the manufacturer, and then need to get it installed. Unfortunately, depending on the part, you could be waiting weeks or even months.
The solution? Century can assist to monitor and maintain the proper parts inventory levels at your facility to be available when needed.
The upfront cost of a spare part is negligible compared to the monetary loss of a system shutdown until the part is received and installed.
5. System Retrofits and Modernization
The business drivers of a facility operation are constantly changing with things like labor shortages, SKU proliferation, and the shift to e-commerce fulfillment changing order profiles and product handling requirements. This often requires adjustments to existing systems to accommodate these changes.
Technology is always advancing very rapidly in the material handling industry. Automation is constantly being upgraded to something faster, more efficient & accurate providing improved throughput and functionality.
As demand for distribution efficiency increases due to many influencing factors, now may be the time to evaluate your system. Adjustments can be made piecemeal to keep overall system costs lower, but still benefiting the functionality and efficiency of your system.
Don’t find your operations stalled and unable to produce the scheduled output. Build a maintenance plan, explore support and emergency options, keep a spare parts supply stock, and retrofit older systems. Century Conveyor Systems is dedicated to the integrity of your operations. We offer all these services and more as a full-service automation integrator. Bring us your problems and we will work towards an innovative solution, together.
“Exceeding customer expectations is the key to our success. We’re not satisfied with simply selling conveyor systems, we want to help you grow your company to reach its full potential.”
Century Conveyor Systems, Inc. is a nationwide systems integrator that has been providing Material Handling Systems, Installation, and Conveyor technical services since our founding in 1981. In 2017, Century Conveyor Systems was acquired by Lafayette Engineering Inc., which enabled us to grow and become an even more capable company with the ability to self-perform most of the work required for turnkey automated system solutions.
As a turn-key system integrator with many successful projects under our belt, we serve a variety of industries including: warehouse/ distribution centers, ecommerce facilities, beverage distribution, retail DC’s, plants, pharmaceutical, and various other manufacturing facilities. Our solutions are second to none allowing us to offer you a full-service approach for every project.
Through combined strategic planning and resource allocation with Lafayette Engineering, we are able to provide full project life cycle services that include System Design, Concepts, Project Implementation, and Operational/Technical Support based on specific client needs. We also offer a variety of in-house solutions such as PLC Controls (Programmable Logic Controller), Warehouse Control Systems for Semiconductor Processes Automation Consultations, or Installation. All projects come equipped with 24-7 On Site Service by qualified engineers who can get there quickly when you need them most.
Century Conveyor Systems, Inc continues to be a top engineering and integration company for material handling applications and systems in the U.S., with our strong dedication to ethical business practices and customer satisfaction. We work hard every day to maintain this status by producing valuable products that are essential for today’s leading manufacturing and distribution businesses.
With so many people buying online, the e-commerce industry is booming. This may be time to update your facility and increase efficiency.Call us for a quote today.
Salson Logistics is a port-to-shelf 3PL logistics services provider, servicing large retailers and consumer brand products. Their customer-focused capabilities and their desire to provide and accommodate their customer’s needs led them to seek a more automated solution for their warehousing operation. Salson determined that their most pressing requirements were to increase accuracy and provide not only greater throughput but to be able to accommodate various carton identifiers, while still employing a common software system solution. The Material Handling system solution provided by Century Conveyor provided for an accurate read and receipt of inbound merchandise leading to a cross-dock sortation application, allowing hand palletization as well as direct truck fluid loading.
Prior to the automated system, Salson had employed a rather manual process, with very limited conveyor automation. Upon receipt, labels were manually applied. Scanning and sortation were performed manually. All products were then hand palletized prior to disposition. Despite the reliance on manual operations, and multiple shifts, Salson was able to achieve daily volumes of up to 20,000 cartons per day.
Century along with Lafayette Engineering was able to provide an integrated systems solution that allowed Salson to achieve the receiving rates and cross-dock sortation rates necessary to provide Salson a solution that allows them to process 35,000 cartons per seven-hour shift or over 100,000 cartons over three shifts.
The Century / Lafayette team solution provided for all aspects for turn-key development, including such key functions as the warehouse control system, material handling hardware, physical implementation, controls, software, and the engineering and project management disciplines necessary to ensure a timely and correct final commissioning, startup and turnover.
Some of the features of this system include traversing trailer unloaders, allowing five traversing unload conveyors the ability to service multiple inbound dock doors, Receiving scan tunnels, on each pair of receiving lines that allow for the capture of all carton received merchandise, ( can scan all sides of carton except bottom) along with no read divert for correction, right at scan location. 16 cartons per minute rate at each receiving location. Upon receipt, cartons accumulate and are queued up on indexing slug belts prior to a merge point. Five accumulation lanes feeding a merge, provide for an outbound rate of 95 per minute.
Merge releases to a bi-directional slat sorter where cartons are read. Thru the WMS/WCS communication, 95 cartons per minute run through the bidirectional sorter which has 23 left hand palletizing divert lanes and 12 right-hand fluid load truck fill lanes, along with another 10 hand palletizing lanes. Palletizing lanes having provisions for hand scanning with label generation for manifesting.
Recirculation is provided for lane full, truck changeout process and other purposes.
The Century/ Lafayette solution provided Salson the key operational features such as reduced labor cost, a vastly higher thru-put capacity, and greater inbound and outbound accuracy. The system’s main benefit in providing a flexible design, beyond greater accuracy and increased capacity has allowed Salson to the ability to take on additional clients.
Barnes & Noble, a Fortune 500 company, is the world’s largest bookseller. In addition to extensive Internet sales, they operate at the time of writing they operated approximately 800 stores in 50 states. The logistics of timely store replenishment and rapid, accurate fulfillment of Internet orders presents an enormous challenge at this level of business.
In 2003 the Barnes & Noble design team, senior members of their Operations and IT groups, under the direction of William F. Duffy, ( former ) Executive Vice President of Distribution and Logistics, engaged the services of the consulting group Kurt Salmon Associates. Together, B&N and KSA began to define all of the capacity and performance requirements of a new mega East Coast Distribution Center to be constructed in Monroe, New Jersey.
Century Conveyor Systems, Inc., a New Jersey-based Hytrol systems integrator, was awarded the contract for integration and supply of the carton and tote materials handling system. The design team, now joined by Century Conveyor Systems, Inc., finalized the operational details and implementation plan for the new system. At the same time, the construction of the 1.2 million square foot facility was underway and on target for a December 2004 completion.
The distribution center houses over 1 million book titles in quantities ranging from multiple trailer loads of popular titles to one or two volumes of very obscure books. Accordingly, inventory storage media varies from high-rise, narrow aisle pallet rack to flow rack and finally to acres of multi-level shelving.
Virtually all aspects of the distribution process are automated. Tracking labels are generated and automatically applied to cartons at receiving. Multiple sortation systems deliver inventory to storage and picking locations. Batch picking is directed by RF interface and routed through zones by scanner directed diverters. Book orders are simultaneously assembled from each picking batch by tilt tray sorters.
Over 13 miles of Hytrol conveyor carries cartons and totes through all of the distribution processes, from receiving to shipping. The entire system is monitored from a central control room equipped with displays that indicate the status of all areas of operation.
For receipts of less than pallet load quantities, inbound cartons are conveyed to a mezzanine above the receiving dock where they are scanned and matched to a database of purchases. A 380-foot long Hytrol Prosort shoe sorter directs cartons to a series of receipt processing and audit stations. After processing, cartons are reintroduced into the receiving sorter for routing to pick locations, cross-dock, or active order fulfillment. Sortation is performed at rates up to 140 cartons per minute.
Forward pick locations and shelving mezzanines are supplied by a series of conveyors and sorters that deliver replenishment inventory. Cartons arriving from either bulk storage or the receiving subsystem are sorted to the three levels, and then by specific zone within each module for put-away to dynamic primary pick locations.
Each of the eight picking modules in the system is three levels high. Order selectors are given location and quantity instructions through scanner equipped radio frequency devices. Within each level, a series of scanners and diverters automatically direct cartons to only those zones where picks are required. Orders that can be completed within a single 3-tier pick module are conveyed directly to carton sealing and labeling stations. Batch picked cartons and totes containing books needed to fill multiple orders are conveyed to the packing sorter.
The packing sortation system is a tilt tray design. Individual books are placed on belts at induction stations and are sorted to chutes that each represents a single order. Indicator lights at the discharge of the chutes direct packers to remove the chute contents for packing as orders are completed. Chutes are reassigned to new orders as subsequent batches or waves arrive at the tilt tray induct stations.
Open cartons, containing completed orders, are conveyed to a series of taping and print & apply stations. Cartons are sealed, weighed, and labeled before they are automatically inducted into the shipping system. Single book orders, selected by batch into totes, are sorted to specially equipped packaging stations for quality inspection, packaging, and labeling before being sent to manifesting and shipping lines.
The shipping sorter is a single loop tilt tray design, capable of sorting up to 170 cartons per. minute to shipping doors and small package Gaylord positions. Shipping door positions are equipped with flexible, extendible conveyors for truck loading.
“Barnes & Noble had previous experience with Hytrol and Century Conveyor Systems, Inc. and we knew Hytrol produced a quality and reliable conveyor. This previous experience was always very positive. Century and Hytrol stood behind their products and services and had become good partners through the years.”
“We had visited the Hytrol plant several years before when we were just starting the project. Meeting the Hytrol team that was going to be working with us on the system gave us a good comfort level.”
“Hytrol and Century made good on all their promises. The product was delivered when we needed it and it all worked out very well timewise. There have been so many advantages to the new system in place. The accuracy, the speed, and the throughput Hytrol affords us has improved our services to our customers. We are very happy with Hytrol.”
-William Duffy, ( Former) Executive Vice President of Distribution and Logistics, Barnes & Noble
Acheiving 99.9% Order Accuracy New picking technology combines with integrated conveyor system to help AmeriSource distribution center reach new levels of productivity and order accuracy.
New picking technology combines with integrated conveyor system to help AmeriSource distribution center reach new levels of productivity and order accuracy.
When you’re in the business that AmeriSource Corporation is in, you have to be fast, efficient, and accurate.
This Malvern, Pennsylvania-based company is one of the country’s largest wholesale distributors of pharmaceuticals and related healthcare products and services.
From a network that includes 19 distribution centers around the country, AmeriSource ships these critical products to hospitals, healthcare facilities, and retail outlets that range from independent drug stores to the big mass merchandisers.
One of these centers-the regional D.C. in Thorofare, N.J., near Philadelphia-recently underwent a major expansion and upgrade to ensure the needed productivity and accuracy. A new conveyor system at the facility, coupled with some advanced automated picking equipment, has led to record performance levels. The distribution center now can handle up to 3,000 totes and 2,300 cases a day with an order accuracy of 99.9 percent!
“The new system has been operating great from the beginning,”says Bob Fillman, manager of systems at the distribution center.”It’s done everything we wanted it to do-and more.” Fillman and his colleagues at the Thorofare facility worked closely with S.I. Handling Systems, Inc. of Eastern Pennsylvania and Century Conveyor Service, Inc. of South Plainfield, N.J., in designing the system. Century is an experienced systems integrator and distributor of Hytrol Conveyor Equipment.
Streamlining the Flow
The new distribution center actually is a 156,000 square-foot expansion to an existing warehouse. That original facility, now used as a replenishment and full-case storage area, was a largely manual operation. But with AmeriSource’s business growing steadily, it had been struggling to keep pace with order demand.
In creating the new distribution center, management wanted to automate a large portion of the picking process and at the same time streamline order flow. Those objectives were accomplished through the combination of advanced computer controls, automated picking equipment, and a network of Hytrol conveyors that feature the EZ Logic accumulation system.
The order-fulfillment process begins in the order origination area where operators scan the packing slips and select one of three types of totes depending on order size. Each tote carries a permanent bar-coded license plate that will direct it throughout the order-fulfillment process.
The totes are inducted into the system on a powered conveyor where a shipping label is generated. After scanning, the totes travel on a belt conveyor to a deflector arm that moves them to one of three accumulation conveyer lines (Model 190-SPEZ). These units have the EZ Logic feature, which senses product presence and controls the accumulation and release of product from zone to zone. The three lines provide the ability to segregate the totes by order size, manual or machine pick, replenishment priority, and so forth.
The totes then merge onto another accumulation conveyor prior to being sent to one of two picking areas in the main building. Totes containing orders to be picked manually travel on a powered takeaway unit for entry into the manual pick area. Totes with orders for machine-pick are diverted to the left by a pneumatic pusher and travel onto an accumulating conveyor to the “A-Frame” automated picker.
The manual picking area consists of a loop of powered conveyor that directs the totes to the right picking zones. Each of the eight zones consists of a series of flow rack and shelving units housing a variety of SKUs.
Once the manual picking is completed, the totes move onto an accumulation conveyer and head toward the machine picking area. A scanner identifies which orders are complete and which need further picking in the A-Frame. Completed orders are diverted by pneumatic pusher toward the weighing and strapping machines. The remaining totes travel straight ahead onto an accumulation conveyor where they enter a queue triggering the selection process in the A-Frame.
All completed orders pass through automated weighing and strapping stations. Once the totes are secured, they move on an elevated belt conveyor en route to the shipping sortation area.
The shipping system consists of a re-circulating loop of elevated power conveyors and a series of nine powered and gravity dispatch lines. The main live roller unit has nine high-speed diverts that direct the orders down the shipping lines. One important feature of the shipping area is the full-line sensing photo-cell. If a dispatch line becomes too full, the photo-cell automatically senses this and directs the order to the recirculation conveyor until the congestion eases up.
In addition to the two main picking areas, the AmeriSource facility includes a replenishment and full-case line picking section in the adjacent original warehouse. A powered roller conveyor brings these items through an opening in the wall and on to either the replenishment areas or to shipping. These cases accumulate in the shipping section where they can be merged with the tote orders.
The operation is not only streamlined and accurate, it’s also clean. An overhead trash takeaway conveyor from Hytrol (TH model) runs through the picking and replenishment areas efficiently removing corrugated and packing material from the work areas.
Big Benefits, Fast Payback
Thanks to the advanced picking technology and the smooth-running conveyor operations, the Thorofare distribution center has been able to keep on top of the steadily growing order volume ever since it went into operation in late 1997. This high growth pattern is not expected to change anytime soon. But as systems manager Fillman points out, that should not pose any problems.
“This operation could easily handle double the current volume,” he says. “We have the system and controls in place. It would mostly be a matter of adding some additional people.”
In addition to being well positioned for the future-and performing at that 99.9 percent order-accuracy level right now-AmeriSource has enjoyed another benefit. Payback on the new distribution center has been realized in a short 15 months.
The AmeriSource Distribution Facility
Order-fulfillment in the main 156,000 square-foot center begins at the order origination area. The scanned totes move through a series of powered conveyors either to the manual or the automated picking areas. Once the orders are completed, they travel through weighing and strapping stations on to shipping. The shipping area has a re-circulating loop of elevated power conveyors and nine high-speed diverts that direct the orders down the shipping lines. Full-case and replenishment merchandise also is transported by conveyor from the adjacent building and integrated into the storage and shipping operations. An overhead trash takeaway conveyor runs through the picking areas. Throughput is currently at 3,000 totes and 2,300 cases a day.
A Closer Look At The Distribution Warehouse
Company: AmeriSource Corp. Facility: Distribution Center Location: Thorofare, NJ Size: 156,000 square feet Employees: 168 (three shifts) Systems Manager: Bob Fillman Product Handled: Pharmaceuticals and health care products Throughput: 3,000 totes; 2,300 cases a day Shipment Method: Primarily LTL Types of conveyors: Live roller and accumulating Conveyor Supplier: Hytrol Conveyor Inc., Jonesboro, AR Systems Integrator: Century Conveyor Service, Inc., South Plainfield, NJ
Low Maintenance, Reduced Manual Lifting Utilization of work stations and multiple conveyor systems produce a system of operation ergonomically safer and more cost-efficient.
Three and a half years ago, F. Schumacher & Co., a distributor of renowned Waverly fabrics, Schumacher fabrics and wallcovering, and manufacturer of high-quality home fashion decorating accessories decided to upgrade and automate their production operations. Mr. Bud Randall, Corporate Facilities Manager responsible for overseeing this entire project from concept to completion, contacted Century Conveyor, Inc., a Hytrol sales & service center based in South Plainfield, New Jersey.
Based on past projects Century had completed, F. Schumacher & Co., was very confident that Century Conveyor Service, Inc. working with Mr. Randall could provide them with assistance in the design and layout of a conveyor system which would be cost-effective and efficient. Schumacher & Co. elected to construct a new 526,000 sq. ft. distribution facility in Richburg, South Carolina. The objective was the consolidation and relocation of their distribution operations for several of their facilities located in various parts of the country.
A primary concern of F. Schumacher & Co. was the automation of the material handling portion of their product line. This included handling of fabrics, wallcoverings, bedspreads, curtains, and pillows. Before the installation of the system, the majority of their production operations were handled manually, involving a great deal of lifting, and moving of products by carts.
Through the utilization of work stations and five individualized conveyor systems, Century and Hytrol greatly reduced the manual lifting requirements and produced a system of operation which was ergonomically safer and cost-efficient.
Integrating a variety of HYTROL conveyors, five independent systems were created:
SYSTEM 1 – Transporting of “ready to ship” cases from the home fashion production areas to a staging area for shipping
SYSTEM 2 – Three packing lines for conveying rolls of fabrics
SYSTEM 3 – Wallcovering packing line
SYSTEM 4 – Heavy freight line
SYSTEM 5 – Shipping line for sample books of fabric and wallcoverings
Since its installation, the system has run perfectly. F. Schumacher & Co. has been very pleased with the system’s reliability and low maintenance, and Mr. Randall highly recommends the use of Hytrol equipment.
The nature of products here required the use of a variety of conveyors. In some cases, the live roller was used for general transportation of boxes. In other areas, belt conveyors were used for transporting unboxed items. These slider bed units are also quieter. Heavy-duty 20-CR and 2514-CRA were used for conveying and accumulating heavier loads. Finally, boxes waiting for shipment are moved by an ABA zero pressure unit or in some cases a gravity unit.
System #1 starts in the sample manufacturing area. It uses a Hytrol Model SP. Items packaged in the home fashion area or showroom samples, using a special container, travel via an incline and ABA to the shipping area. LRC curves are also used and, to avoid accumulation in these curves, a photo-eye senses when the conveyor is full and shuts the unit down.
System #2 consists of three packing lines for fabrics. Fabric orders are picked from static shelving, placed in a cart, and pushed to a cutting station. There, the fabric is cut according to the order and placed on a roller bed belt unit which takes it to the packing station. The packer can control or feed items as needed to that station. After packing, they are placed on another roller bed conveyor which takes them to a scale area. Roller bed conveyor was preferred here because of the potentially higher loads. Some of the RB conveyors used a TW type frame which was more eye-pleasing and had no protruding edges. At the end of the packing conveyor are a scale and an operator who weighs the roll. The operator pushes the roll off the scale onto a conveyor with a flipper. The roll is then moved on a 5 ft. wide cleated belt which takes it to a rack. This rack travels to UPS and is returned after emptied.
System #3 is the wallpaper line. Wallpaper is picked from storage rack and placed near the packers who put the rolls of paper in boxes. Boxes are then placed on the conveyor. There are two slider bed Hytrol TL units side by side with work stations on one side. These belt conveyors end at a wide 20-CR (chain roller). The chain roller has a plow mounted to it controlled by the scale operators. These operators move the plow the direction necessary to get work in process. The 20-CR was used to provide good traction for diverting the heavy boxes. After the 20-CR, boxes accumulate on an ABA zero pressure waiting for shipping.
System #4 is the heavy-duty line for boxes of fabric weighing up to 400 lbs. Again, rolls of fabric are brought to the packing stations next to the conveyor, a 20-CR, used to best convey heavy boxes. At the workstation table, boxes are loaded and sealed. When finished, a set of rollers extending from the table to the 20-CR can be lifted by a foot-operated pedal. Boxed are then pushed onto the 20-CR. When the rollers are lowered, the box travels to the scale and strapping area. A break belt is located before the scale. When the operator calls for it, the box transfers to the scale is weighed and then sent to the binder. The binder bands it in one direction transfers it at 90 degrees with a heavy-duty push-off, bands it in the other direction then conveys it to a gravity line for removal by a lift truck.
System #5 is used for processing sample books of fabric and paper. Samples are staged on a gravity conveyor, transferred to a short Hytrol 1.9-SP then to an ABA via a special pop up o-ring transfer. Samples not boxed travel through a shrink wrap machine before shipping.
Recycle Ink- Full function industrial container management
Conveyor System Upgrade Increases Throughput Faster order-picking and increased flexibility improve order-filling accuracy.
Full-function industrial container management
Conveyor system automates container handling operation
When Recycle Inc. had the opportunity to design a new container processing plant from the ground up, an automated conveyor system was high on the list of priorities. Company managers wanted to replace a largely manual handling operation with a conveyor-based approach that would be both more efficient and safer.
Based on the new facility’s first few months of operation, they were right. Employee productivity climbed 20% just in the first week of start-up. Throughput projections predict that the new plant will process four times as much material as the old plant did in the same amount of time and with the same number of employees.
Jeffrey Bey, President of Recycle Inc., cites several reasons behind his company’s decision to switch to automated handling. “Essentially what we are is a manufacturing operation,” Bey explains. “We use one process to wash and prepare containers that will be reused, and another process to shred or granulate containers that are to be destroyed.
“Our incoming ‘raw materials’ are the containers themselves. These containers — especially the larger ones — tend to be unwieldy, and some of them are fairly heavy. In the past, we handled the containers manually at several points during processing. Given our throughput requirements, we had the potential for accidents, and our approach wasn’t very efficient. As the demand for our services escalated, we knew that we needed to come up with a completely new way of handling containers — one that would take advantage of the benefits offered by automation.”
After the company located a suitable building for a new facility in South Plainfield, New Jersey, Bey assembled a project team to study new materials handling methods. The team contacted several nearby conveyor distributors for design ideas. According to Bey, some distributors balked at the idea of getting involved in up-front design work without first being assured that they would get the job.
“We were looking for ideas,” says Bey, “and we were also looking for a distributor and a conveyor manufacturer that would partner with us on this project.” Fortunately, the local Hytrol Conveyor distributor, South Plainfield-based Century Conveyor, didn’t hesitate to tackle the project.
Working closely with the project team, representatives from Century Conveyor, from Hytrol, and a nearby automation firm designed a conveyor system that combines powered conveyors with smart sensors and custom software. At every decision-point in the system, sensors supply feedback to the control program on the movement of individual containers, on the performance of the conveyors, and even on the maintenance requirements of the sensors themselves.
A Whole New Approach
At the company’s old processing facility, employees did a lot of the handling of incoming containers. The plant did have a conveyor system in place, but it was a single straight-line design that simply transported the containers from one workstation to the next. The old conveyor system did not include any powered transfers or spurs.
The design of the new conveyor system at the South Plainfield facility greatly reduces the amount of manual handling by relying on automated conveyors to move the containers.
The new plant inspects and cleans 5- to 85-gallon polyethylene containers and intermediate bulk containers (IBCs) for reuse. Also, it provides certified destruction of 5- to 85-gallon polyethylene, steel, and fiber containers, and of IBCs.
Incoming containers are transferred from trucks to one of four takeaway conveyor lines. Based on their composition, disposition and on whether they will be prepared for reuse, the containers are carried by the conveyors to several possible destinations.
Containers that are to be reused are conveyed to an inspection loop where employees evaluate their condition. Powered roller conveyors then carry the containers that have passed inspection to one of three fully-automated washing stations. After washing and another inspection, the containers are ready to be returned to their owners for reuse. All of these containers are captive within a closed-loop system between their owners, customers, and the South Plainfield plant.
Containers that are slated to be destroyed are conveyed to other workstations within the building for processing. In this part of its operation, the facility handles containers made of steel, polyethylene, or fiber.
Conveyors carry steel containers to a shredder; the scrap metal that is generated goes to electric mini-mills to be made into reinforcing rods for use in concrete construction projects. Polyethylene containers are ground into pellets which are then sold to be made into various corrugated plastic products including plastic drums. The fiber containers are conveyed to a workstation where they are broken down before being supplied to a paper mill for recycling.
Except for the belt conveyors that carry materials to waiting trailers, nearly all of the conveyors used in the new system are powered roller. Strategically-placed accumulation sections control the grouping of the containers before being transferred to workstation infeed conveyors. At two points, powered turntables rotate the containers 180 degrees (see drawing).
“This new system is enabling us to process 80,000 containers per month with almost no manual handling,” notes Bey, “and it can handle a lot more. So in addition to being far more efficient and having a much greater throughput capacity, we now also have a facility that’s substantially safer for our employees.”
Recycle Inc.’s new 86,500 sq. ft. processing center
Incoming containers are loaded onto four takeaway conveyors in the receiving area. The containers are conveyed either to inspection and washing or to shredding or granulating. The containers that are to be reused are delivered to their owners after being washed; materials from destroyed containers are hauled to recyclers to be made into other products.
The new facility at a glance
Company: Recycle Inc. Location: South Plainfield, N.J. Nature of operation: full-function industrial container management Services provided: container inspection, cleaning, dedicated reuse, certified destruction Total square feet: 86,500 Number of employees: 70 (company-wide) Types of containers handled: 5- to 85-gallon polyethylene containers; intermediate bulk containers (IBCs) Types of containers destroyed: 5- to 85-gallon polyethylene, steel, and fiber containers; IBCs Number of containers processed per month: 80,000 Design conveyor throughput rate: 10 drums per minute Maximum daily throughput: 6,000 Accumulation sections: Chain driven live roller Conveyor supplier: Hytrol Conveyor Company, Inc.-Jonesboro, Arkansas Equipment distributor: Century Conveyor Service, Inc.-South Plainfield, N.J.
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