7 Conveyance Solutions for Robust Handling of Various Product Types

ARB Solutions 2

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.

  • Sortation
  • Depalletizing
  • Singulators
  • Merges
  • Switching
  • Zone Picking
  • Infeeding and Outfeeding

1. Sortation Systems

DARB S4500 Sorting Belt

90-degree sortation

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.

ARB Sorter S7000

Bulk sortation

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

ARB Pallet Layer Descrambling S400

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.

3. Singulators

ARB Singulating Belt

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.

4. Merges

Polybag ARB Merging

Polybag merging

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.

5. Switching

Polybag Switching and Aligning

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

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

Infeeding and Outfeeding ARB

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.

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Post-COVID Parcel Customer Expectations

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How automation solutions fulfill today’s parcel shipping demands

post covid parcel expectations automation solutions

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

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.

Cross-belt

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.

Narrow-belt

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.

Shoe Sorter

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.

Split-tray Sorter

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.

Push-tray Sorter

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

pullquote graphic parcel industy automation

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.
parcel industry customer shipping expectation stats

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.

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5 Economical Ways to Avoid Conveyor System Downtime

blog header for conveyor service and repair
system downtime blog graphic

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 shipped 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).

system downtime costs quote

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 Conveyor Systems 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? Allocate some space in your warehouse (ideally a small section of shelving) towards spare parts. Proactively order components and replenish anything that is used. This can span from common cables and photo eyes to large motors and compressors.

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.

If you’re looking to stock up on spare conveyor parts, we may be able to help out.

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 benefit 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.

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Our Conveyor Systems & Services Help Companies Maximize their Potential.

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“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.”

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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.