Material Handling Support for Robotics and Warehouse Automation

Rolling with Automated Conveyor to Boost Automated Processes

When it comes to warehouse automation, customers often seek out robotic equipment, pallet stackers, and even fully automated storage and retrieval systems (ASRS) to more efficiently perform specific tasks. Adding conveyor systems to the process can further increase the speed and functionality of automated processes and further drive down operational costs.   

Automated Conveyor Options

• Accumulating conveyor
• Automated repack or sort
• Goods-to-man system
• Conveyor fed ASRS

The most basic system is a powered accumulating conveyor with zones of transfer. In simple terms, the pallet is either loaded onto or unloaded from a series of powered conveyors that are programmed to move the pallet forward to the next empty zone for pick-up or drop-off. This is accomplished with a series of roller conveyors linked together with photo eye sensors that read the pallet to move it forward until it can no longer go anywhere. Accumulating conveyors help control the flow of inventory or products through production or processing. The conveyor will automatically stop or start the flow using sensors in pre-designated zones. This feature is helpful in metering or batching loads or allocating the pallet to storage.

Accumulating Conveyor Applications

• Manual workstations
• Robotic palletizers
• Sorters
• Merges 
• Robotic Assist

Automated Repack & Sortation 

Goods may come into the warehouse on one pallet but leave on another. The process of customizing pallets for order fulfillment includes three steps: 1. Sorting 2. Picking and 3. Repacking. Automate the process by having accumulating conveyors move the pallet to a staging area where it is de-stacked. The product is then placed on smaller powered conveyors that advance to another station for repacking. A robot or lift secures the empty pallet and puts it on an adjacent accumulating conveyor designed to feed a pallet stacker. Once the desired number of pallets are collected, the pallets are discharged from the stacker and picked up by forklift or pallet jack.   

Goods-to-Person Powered Product Conveyor:  Tote or boxed packaging

Traditionally, order picking requires the associate to travel to the stored item and then bring it back for packing. That process can expect a 60% – 40% split of time spent traveling vs. picking. Automating the process and bringing the goods to the associate can significantly increase pick rates and reduce costs. Powered conveyors are an effective goods-to-person option. 

Workers can pick items for repackaging onto pallets for production or storage or placed directly into cases for pack and ship. The goods-to-man conveyors continuously run in a loop so the associate can pull parts for packing. They can increase storage density upwards of 60%. SKUs are slotted to optimize the picking function and ensure fulfillment accuracy. Typically, there are multiple repack stations so associates can pull a variety of product as it passes along via the conveyor. 

Automated Pallet or Mini-Load Storage

Conveyors can boost the productivity and safety surrounding your automated storage and retrieval system (ASRS). An automated conveyor used to intake pallets into an ASRS system minimizes forklift traffic and possible system damage resulting from equipment strikes. When pallets are retrieved, they can be deposited onto the conveyor to flow to the staging area, again eliminating the need for forklifts to collect and transition the pallet. The conveyor is controlled by the operating system to help regulate the pallet intake and discharge within the ASRS system.

Turnkey Design and Installation

WOI offers full-service design and installation of powered automated conveyor systems. Each application varies from client to client. Our team looks at each individual project and its objectives, and then we make a recommendation. Our proposals include installation, electrical, and start-up of the system. Our goal is to deliver a complete functioning system that accomplishes our client’s goals for the system.

Let WOI Make the Right Connections

Warehouse Optimizers, Inc. (WOI) is a leader in integrating warehouse automation systems with roller conveyors to maximize productivity. Our team provides full-service support from system design, licensed general contracting, permitting and scheduling, to professional installation services. Our Satisfaction Experience guarantees success.

The WOI 5-Step Total Satisfaction Experience™ guarantees that we will 1. Listen to your needs, 2. Execute your project with particular attention to your unique application, 3. Stick to project timelines, 4. Ensure a safe environment, and 5. Pay close attention to the appearance of the finished product. 

The WOI team will walk you through each stage of the process and provide expert customer service to deliver outstanding results and peace of mind. Contact a member of our team today, and let’s chat or Zoom. Call (865) 540-4004 for a prompt response.

We proudly serve customers throughout the Southeast, including KENTUCKY, TENNESSEE, NORTH CAROLINA, ALABAMA, AND FLORIDA.