Advanced Packing and Sorting System

Conveyor Systems Ltd (CSL) helped a leading E-Commerce customer to upgrade its packing and sortation system to meet increasing levels of consumer demand. CSL designed and installed a start-of-the-art, multi-stage, high speed crossbelt system which assisted the company in sorting and packing over 180,000 orders a day.

The customer is a top E-Commerce retailer in the North West of England that processes online orders at a staggering rate of 7500 items per hour. The project involved handling a very diverse range of products such as cartons, cardboard envelopes, polybags and jiffy bags. All of these items were to be processed by 120 operators on a 24-hour shift basis so all upgrades had to be completed without fault and with minimal downtime.

Previously, the client faced challenges due to the extensive use of manual labour for packing and sorting items for shipment. This approach often resulted in delays to dispatching items or, even worse, occasional damage to products. After consulting with multiple solutions providers, the customer selected CSL as its preferred supplier.

CSL understood that a state-of-the-art packing and sorting system needed to effectively utilise floorspace whilst ensuring the speedy, secure delivery of products along this packing line. Additionally, the customer needed to be able to track and monitor the position of goods along the sortation line to make sure that all packages were delivered to the correct final destination.

To meet this challenge CSL worked with its customer to design a sortation system that featured eight product packing lanes, each outfitted with 15 packing benches. Packed products from each of these lanes were then transferred onto the main transit line using multi-speed metering belts and mitre belt merges.

The main transit line weaved its way through the building, taking a 90-degree turn before ascending to a height in excess of 2500mm. This arrangement allowed for operator movement beneath the system, maximising the efficiency of the flow of people and products.

Upon reaching the higher level, each product underwent scanning through a SICK scanner array. The relevant information was relayed to and from a cloud-based server, providing CSL with a precise destination lane for each item. The packages were subsequently indexed via a multi-stage belt system onto a high-speed vertical cross belt sorter. This sorter housed 44 destination chutes, including a run-out chute for barcode misreads and orders requiring special attention.

Using the sorter’s control system, the customer could assign a specific sort location to a dedicated chute. Each chute was fitted with an indicator beacon, which notified the operator about the chute’s status. If a chute reached 75% or even 100% capacity, the system could automatically redirect packages to a previously selected destination.

Other upgrades included adding two desktop PCs with Scada operator interfaces which allowed for remote, real-time system operation and the installation of two bespoke access platforms to maintain operator access to the main fire exits.

Mike Graham, Managing Director of CSL, explained: “We are overjoyed with the results we were able to achieve for our valued E-Commerce customer. The installation, testing, and commissioning of the entire system showed CSL’s commitment to operational efficiency and customer satisfaction as we were able to complete the project within a 19-week period and worked with our customer to ensure a seamless changeover to the new packaging and sorting system.”

Modular Pallet Platform Upgrade

Interroll, a global leader in innovative material handling solutions, has enhanced its Modular Pallet Platform (MPP) to meet market demands for an increased load capacity, enhanced energy efficiency, reduced complexity of design and improved storage options for warehouse facilities.

Designed to revolutionise pallet handling, the MPP is a fully configurable system that offers reliable and efficient streamlined material flow. It is capable of transporting heavy pallets with ease, with a maximum weight capacity of 1,500 kilograms – increased from 1,200 kilograms. Tested to 1.5 million cycles at 1,500 kilograms, the system has been put through its paces and proven to operate without failure to the equivalent of 3 years of average use.

With a top of roller height starting from just 95 millimetres on some modules, the conveyor solution can be easily accessed by hand pallet trucks and forklift trucks, simplifying the process of loading and unloading pallets. The modular system offers a range of assembly heights and conveyor widths to fit individual customers’ specifications. Its Pallet Drive conveyor is available in a flat version with an integral motor. This saves space, reduces maintenance, and simplifies the conveyor’s overall design.

To transport pallets effectively, the MPP range includes modules such as 90-degree transfer units, and rotary turntables with encoders for accurate positioning. New advantages of transfers and turntables include simplifying the design and making installation and commissioning easier and faster. Transfer cars and stacker cranes offer a seamless interface with Interroll’s Dynamic Storage platform taking pallets from production to warehouse storage automatically.

Hilton Campbell, Managing Director of Interroll UK said: “MPP is the ideal solution for any end-user that wants to maximise operational space and efficiency. We’ve listened to feedback and have made improvements to the platform that tick off many of the points on our customers’ wish lists. Our aim is to use the available space more intelligently while minimising transportation times between different areas such as goods receipt, goods issue, storage, production, and picking areas. By automating these processes and simplifying planning, end-users can operate more efficiently.”

Operational and energy efficiency are key drivers behind the 2023 upgrades to the MPP. Energy-efficient DC drives are installed with options for decentralised conveyor systems via the Multicontrol and Pallet Control units. Gravity-powered rollers for dispatch lanes or accumulation conveyors utilise patented Magnetic Speed Controllers (MSCs) that use an eddy current braking system.

Interroll control devices for MPP utilise an analogue interface which enables Interroll’s zero pressure accumulation conveyor technology to be integrated into Industry 4.0 systems. This enhances overall automation functionality, data management, and operational efficiency.

OEMs, system integrators and end-users can benefit from Interroll’s layouter tool that quickly generates 3D layouts to see how the Modular Pallet Platform would work in the space available before ordering components. The tool generates a 3D model of the complete materials handling flow, allowing engineers to tweak the design and alter components to configure the perfect solution. A detailed Excel spreadsheet can be exported that details drives, sensors and specifications of all modules providing controls teams with accurate information to design their control systems.
Once the design has been confirmed, installation of the MPP is simple and straightforward, with the perfectly matched pre-assembled modules fitting together seamlessly. The modular nature of the system also enables easy and cost-efficient changes or upgrades to the material flow system in the future. Due to design simplicity, faster installation and commissioning can be achieved compared to previous versions, saving valuable time on site.

Campbell added: “The upgraded Modular Pallet Platform offers our most flexible solution for pallet handling. Customers can expect seamless material flow, high capacity storage, and enhanced productivity across a wide range of applications.”

Its optimal operating temperature ranges of -28 degrees Celsius to +40 degrees Celsius mean it can be used in a wide variety of warehouse environments, from ambient to deep-freeze environments.

New Managers join Interroll team to Strengthen Innovation

New managers with a strategic innovation focus have recently joined the Interroll team. The company also established its Innovation Projects and Development Center (IPDC) in 2019, which sits at the heart of its innovation process.

New Interroll Head of IPDC Dr. Christopher Matheisen took over responsibility in August 2020. For more than 10 years he has worked in various research and development (R & D) roles. His professional career comprises being cofounder and Chief Technology Officer (CTO) of a successful start-up in the field of sensorics, and then serving as R&D Platform Manager for autonomous driving at Saint-Gobain Sekurit (Automotive). He has proven competencies in project, resource, and budget management as well as interdisciplinary technical knowledge in electronics, mechanics, and software.

New Interroll Head of Intellectual Property (IP) Stephan Kohlhof  assumed his position in mid-August 2020. An engineer in mechatronics, he has worked for more than 10 years as a German and European patent attorney. Before his appointment at Interroll, he was Head of IP Team Elevator Technologies at the JUVE 2019 award winning in-house IP department of Thyssenkrupp.

Matheisen and Kohlhof report to Dr. Christian Ripperda, Vice President System Innovation at Interroll. Ripperda was appointed innovation lead at the beginning of 2020.

“We are pleased that with Dr. Matheisen and Mr. Kohlhof, two renowned experts will contribute to further strengthening Interroll’s ability to innovate. Our innovation capacities play a key role in enabling our customers with products and solutions that offer quality, speed, and easiness, and strengthen our position as a thought leader within our industry,” says Ripperda.

CEO Paul Zumbühl stepped down as Interroll’s CEO earlier this year.

Interroll reported improved profits in the first half of this year, despite a slow-down in the number of orders.

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