Ozone.bg is a leading eCommerce business in Bulgaria, focused on the growing gaming industry, video games, music, movies, technology and IT hardware.
Products of the company can be found in the now typical combination of physical stores in Sofia, Plovdiv, Varna and Burgas, and on a very well developed online, eCommerce platform, reaching the end customer 24/7. This opens the possibility for thousands of online sales and orders to their logistics base, simultaneously.
At the same time, consumer behavior is changing. Custumers are shopping online very often. Phisical stores also need their supplies.
Years ago, Hristo Urumov, owner and manager of STAMH, which specializes in the building of logistics centers, predicted that “for some distribution and logistics hubs, the new situation would be extremely complicated, unless their managers make changes. These centers will start receiving more orders per day than they can physically fulfill”.
Huge increse in the orders volume
With the beginning of the pandemic situation, and not only, the number of orders eCommerce companies in Bulgaria have to prepare is rising. The comparison between the last “normal” week – the one from March 2 to 8 and the one from March 23 to 29, shows a 55% increase in the number of new online end custumer enquieries. And on days like Black Friday, the average value of 1 order reaches BGN 267. The package may include many different items from the storage facility and has to be prepared in minutes.
In fact, this great news for ozone.bg leads to the urgent need to modernize the company’s distribution center, strategically positioned near Sofia.
The new challenge
As a leader in the construction of fast and efficient conveyor systems, the engineering company STAMH meets the new challenge with no fear. Due to the wide variety of items to be picked and collected in separate orders, as well as the fact that sometimes 1 order includes items from different floor levels, the new solution had to speed up all intralogistics processes and connections between different areas.
STAMH’s engineering and software teams focused their efforts on the distribution center, builded on 4000 sq.m., and devided in sever areas:
Areas and systems for the storage of palletized goods;
Space and systems to store small goods (mainly boxes with dimensions of up to 600 mm. / 400 mm. and height up to 600 mm);
- Orders sorting area;
- Packing areas;
- Expedition areas;
An additional challenge for the leader in automated and mechanized storage systems was the distribution of the facilty in 3 different levels above the ground.
All boxes, packages and trays had to run smoothly between zones and to be automatically distributed to the courier company, responsible for the fast delivery. The packaging units that ozone.bg uses are not the same – the boxes are between 250mm / 175mm to 600mm / 400mm, with heights from 10mm. to 600mm. Their weight also varies from 150 gr. to more than 20 kg.
The new solution form the engineering and software proffesionals
To connect the different levels in the distribution center, STAMH builded a gravity roller conveyor structure. The spiral conveyor doesn’t consume energy, which makes it very ecological and economical. At the same time, it saves operators efforts. They no longer have to cover the distances between different floors. The gravity spiral conveyor, connected the second and third storage levels with the packing and sorting areas, located on the base lavel.
Once, the pre-assembled order or package is packed and ready for shipment, it’s placed along a motorized roller conveyor. This conveyor line drives the package to the area, where it’s automatically sorted and leaded to the area of each courier company. Each package can be placed anywhere along the conveyor line for boxes and trays, allowing exceptional flexibility and the definition of different areas, around the conveyor line.
High technology software and hardware solutions
Orders packages travel along the conveyor line, saving efforts and unnecessary distances, normaly covered by operators. They pass through a special camera device with an in-built barcode scanner, funcioning with impressive speed and intensity, able to recognize conventional linear 1D barcodes and 2D – two-dimensional barcodes. 2D barcodes are smaller, but able to “store” much more coded information.
The wide reading area range of the barcode scanner, allowed STAMH Solutions team to cover the ozone.bg sorting neads. Regardless of the size of the box, the special camera is able to capture moving objects within microseconds. So now, the new conveyor line is able to process and sort, thousands of orders in no time.
PLCs are controling all the hardware equipment. They are conected in an highly efficient ethernet network. They send the necessary information to a special HPD sorting conveyor module. This module allows the automatic sorting of baxes between different couriers, resposible for the delivery. This way, the company responsible for the on-time orders delivery of ozone.bg, recieves the package and deliver it to the very impatient end custumer. Much faster.
Fast intralogistics means satisfied customers
As eng. Nadezhda Blagoeva, Technical Director in STAMH says, “The conveyor system connects different areas and speeds up all processes in the logistics base. In a very intuitive way, conveyor lines organize orders preparation processes.
Warehouse operators don’t have to carry heavy trays and packages, covering long distances. They are organized in different areas and manual work is signicantly reduced. Now, thousend of new orders are prepared much faster and in a more efficient way”.
Thanks to STAMH’s engineering and software teams, the distribution center can now meet the increased requirements of the modern market, both by the end customers of ozone.bg and by the physical stores.
Wiggle eCommerce Fulfilment Centre
Conveyor Systems Ltd completed a major installation supplying an extensive pack and sortation conveyor solution for global online retailer Wiggle Ltd. Operating as the UK’s #1 online Cycle, Run & Swim retailer along with being recently voted the Which? recom- mended #1 online outdoor & leisure shop. In 2015, due to the continuous growth of the business, they took the decision to relocate the Operation to a larger, consolidated Fulfilment Centre (320,000 sq.ft.) in the West Midlands from the multiple small sites operated in Portsmouth.
After a rigorous tender process, CSL’s ability to provide a well demonstrated solution was key to meeting the brief and winning the contract. This included using the latest 3D CAD drawing software to help visualise the system as a lifelike operational representation in the new building.
The brief was to combine packed consignments from 3 pick/pack areas over 3 floors and sort them down 12 lanes into 4 dispatch zones for separate carriers and services. The system needed to cope with up to 90 boxes per minute of varying sizes and weights, from very small parts and clothing up to large boxes of bicycle wheels!
The conveyor system which was specially designed by CSL at over 900mm wide, was engineered in detail after taking into account all comments/ suggestions made by both management and operators at Wiggle together with fully recognising their requirements, considering the vast array of shapes and sizes of products whilst overcoming operational issues.
The mezzanine consists of 2 upper floors which along with the ground floor form three independent pick/pack zones and sortation areas which were designed specifically to avoid issues caused when one combined system is stopped for maintenance/Repairs.
Once an order is picked, packing operatives check the order then pack into an array of outers ranging from poly bags to large cardboard boxes prior to applying carrier despatch labels. The consignment is then placed on a section of zero line pressure (ZLP) accumulation roller conveyor which starts the transit to the sortation area on the ground floor. This type of conveyor is used widely on the system to ensure noncontact queuing due to the wide variety of sizes, shapes and weights causing damage to each other and potentially initiating jams along the system.
The upper mezzanine floors use 2 powered Ambaflex spiral lowerators (almost 100 units supplied by CSL throughout the UK to different customers), to safely and continuously bring the boxes down where they are then barcode scanned to determine, by way of state-of-the-art scanning arrays on each line, which carrier despatch lane they require. When the packages reach the correct despatch lane they are diverted off at 90 degrees using high speed switch sorters. Depending on the source pick floor, they either decline down a grip top belt to an ergonomic picking height or transit on a horizontal roller conveyor to the discharge area where a despatch operative removes and places them onto a pallet or into a wheeled cage ready for carrier collection.
CSL provided the full turnkey conveyor project including control, installation and commissioning of the wide range of packages.
“As this was a new facility it was difficult to visualise the conveyor system prior to the mezzanine floor installation, but CSL provided a detailed 3D drawing which included both the mezzanine and the conveyors which brought clarity to this. The install process was smooth and the end results have allowed us to increase control, flexibility & volumes”
Dan Corrigan, Head of Logistics & Operations Development
New, aesthetic Conveying System for the future
The young Swiss startup Avancon SA (www.avancon.com) has set itself the goal to revolutionize the unit handling systems in distribution and logistics centers. They offer now a new modern and very innovative conveying system. This will be distributed worldwide by manufacturers of conveyor systems and logistic system integrators. The system has been developed by Dieter Specht, the founder of the Interroll Group.The car industry, the computer industryand even the machine industry presentevery few years new and moderndesigned models. Why? To be able toattack new markets and new customers.However, it is hard to see somethingnew in the conveyor industry.
Most ofthe unit conveyor systems weredeveloped 15, 20 or even 50 years agoand are still sold today in a construction,which remembers on the patents of theBritish toy manufacturer Frank Hornby,who has already registered his patent ofa “Meccano” kit in 1901.Now, the two young founders of the start-up Avancon SA are ready to revolutionize the conveyor industry with thisnew and streamlined concept. It’s full of innovative and functionalideas and has been patented worldwide.
Originally, Dieter Specht had developed this systemfor Interroll. But it didn’t fit to their philosophy. So hefound two enthusiastic entrepreneurs, Denis Ratz,he has a bachelor of science in business informaticsand Dr. Daniele Gambetta, who has a PhD inelectric machines. They established inTicino/Switzerland a new start-up under the name Avancon SA (from Avant-garde and Conveyor).
The CEO, Denis Ratz showed the new conveyor system to some large and important manufacturers of conveyor- and logistics-systems and got a very positive response.
“Of course, we wanted to see the reactions to our completely new and very modern designed conveyor concept,” says Denis Ratz. “Most were positively impressed about the outstanding design. I could answer all their questions about the functions and requirements of the market. After these meetings with CEOs and technical managers of big and well-known companies I was highly motivated. Now we are ready. Everything is finished and tested. We can deliver. Several potential customers will visit our large test facility here in Ticino. We believe that the functions and the many advantages of this innovative system will convince them.”
Avancon SA invested heavily into development, in machines, in molds, patents and in the production. With a clever marketing concept enables an exclusive group of Conveyor Manufacturers and System Integrators worldwide to promote the system under their own label/brand and house color to the final market, the operators of logistics and distribution center.
Denis Ratz explains: “We want to offer something avant-garde to the manufacturers of conveyors and intralogistics systems. But we don’t want to interfere with the market of our customers and we will not offer to distribution- and logistics-systems directly to operating companies. Even though this modern system will catch the eye of every manager of this industry.”
The partner and head of technique, Dr. Daniele Gambetta, is an experienced specialist for electronic control and DC-motors. He has patents of completely new DC-motors, which will also be integrated in the future in the Avancon Conveyor System.
“Today – in the digital age of ‘industry-4’ – the electronic connectivity is of enormous importance. I was very fascinated by the ideas of Dieter Specht, so I have joined this young start-up,” says Dr. Daniele Gambetta. “I have never seen such a convincing new concept in the conveyor industry. Everything is completely different, new, safer and much better. We believe that about 80 % of all goods up to 50 kg weight, which have to be transported millions of times worldwide every day, can be handled with this new system.”
Meanwhile, the design has been awarded by the internationally well known “Red-Dot” price in Germany and also by the very coveted throughout Asia, “Good-Design” award in Japan.
The two partners have a lot of courage to break into such an established market today. But who would not want to offer their customers something very aesthetic, even revolutionizing, which differs to all previous designs?
Why aesthetic? Well, ask yourself: would you buy today a machine, which is not modern covered? Now you can offer your customers something extraordinary that combines innovation with emotions.
Denis Ratz says: “We are very positive about the future. We have just moved into a newly built modern factory, which corresponds to our DNA. Here we have a daily capacity production of up to 400 meters conveyor tracks of our new ZPC- system. Anyone who builds conveyor systems by himself can obtain all individual elements from us and so use the patents free of charge. Several customers want to exhibit the new system at one of their upcoming trade fairs.
‘ZPC’ system means “Zone Powered Conveyor” system, in which each zone is controlled and driven separately. The system is extremely flexible and adaptable. It is capable of slow or fast transporting in any desired line and, where necessary, can accumulate without pressure. The system can also communicate with higher IT or Bus system very easily and at significantly reduced installation cost.
Of course it transports goods in all directions, with all the functions an engineer wants for logistics systems.
Last but not least it seems to be much cheaper than it looks.
Automated sortation system installed specifically to deal with “small traffic”
The UKs largest dedicated parcel carrier officially opened its new purpose built, 15,000 square metre, parcel distribution hub in Warrington back in 2014. Designed to support the continuation of growth of the company the new hub has a capacity of around 550,000 parcels a day – almost three times that of the previous site in Warrington.
The facility’s purpose was to help with the developing requirement for next day deliveries, playing a key role in plans for international expansion and to provide a platform for further innovation, as the company looks to introduce a host of new products to the market.
L.A.C Conveyor Systems Ltd is now entering its 4th year, working closely with the multinational delivery company, in the development and implementation of innovative, flexible technologies to suit the ever-evolving challenge of handling parcels from a wide range of shapes and sizes whilst achieving faster processing times.
L.A.C Conveyor Systems innovative
The latest challenge was to introduce a sortation solution specifically designed to accommodate small sized parcels. Prior to the new solution the sortation of “small traffic” was a combined sortation process, with larger parcels. This combined automated parcel sortation approach meant that smaller parcels were harder to control and ultimately ended up being manually sorted. This system required a lot of human intervention to gain full control, proving not the most efficient approach, as the accuracy of the sort could not be guaranteed. Separating smalls from larger parcels meant higher throughputs could be achieved utilising a more streamlined solution with a 100% accuracy of sort.
L.A.C Conveyor Systems innovative “Automation Toolbox” meant a combination of technologies could be combined to satisfy the required solution and could be delivered and implemented within a small footprint and with minimal disruption to current operations.
The solution utilised L.A.C designed induct/feed conveyors, handling bulk parcels on infeed for initial parcel separation, which were then separated further utilising a flighted belt conveyor, leading on to a horizontal conveyor with 5 moveable ploughs and 1 fixed. The parcels were then broken down further spread across 6 chutes, presenting parcels to an operator platform. Operator interaction at this stage of the process provided a means of orientating parcels and placing them onto a Equinox split tray sorter with barcode labels accessible for automated scanning and verification.
The Equinox split tray sorter is a tray-based “bomb-bay” sorter developed specifically to handle flat goods such as packets, books, garments, parcels, and accessories, making it the ideal choice for L.A.C to integrate as part of a turnkey solution. The system offers the capacity to sort 10,000 trays per hour exceeding the requirements, but offering scope for future growth. It has a characteristic oval-shaped conveyor on which the trays circulate. This “open oval” design allows operators and further automation to integrate with ease.
An overhead scanning system ensured parcel identification and location could be achieved at high speed. L.A.C’s modular software design structure offered a seamless link with the host IT system, completing the final piece of the puzzle.
This unique automation approach has ensured a fast and flexible response to future e-commerce demands and has enabled an increased ability to handle parcels of such a shape and size in such a controlled manner. L.A.C’s diverse inhouse skill set has offered a solution that is cost effective providing faster processing of incoming “small” parcels.
Modernising the supply chain network
System to handle small sized parcels only
Cost effective and efficient flow of goods to consumers
Selecting & implementing the best technology
Allow for more next-day delivery
Increased order accuracy
Overall reduction in costs
Integrate with latest supply chain technology
Key services & Technologies
Feed conveyor – shaft mounted motor, tapered hopper to allow product to fall onto flyted belt conveyor.
Modular belt conveyor with hopper
Discharge conveyor with high side for product control
5 off moving ploughs and 1 fixed. Underslung braked motor with pivot arm connected to plough
6 off discharge chutes
6 off operator stations
Each discharge station offering PTL button light module
Double tray wide oval sorter
Sorter gross capacity (10,000 trays per hour)
Tray type 7 DT Double Tray – (Bombay also known as split tray)
Sorter direction – Clockwise
Barcode label control linking carton to station
Item detection sensing
Omni Camera Scanner – Overhead system for barcode label capture
L.A.C IT hardware and Software integration
Wireless network connection
VPN Remote Access
100% Accuracy of sort.
Increased supply chain efficiencies
Sortation direct into shipping cartons
Easy to use, simple efficient design and low maintenance decrease cost and increase uptime.
Design allows for the highest accuracy as well as a very small footprint without losing throughput.
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