Conveyor Systems Ltd (CSL), recently completed the installation of a high-speed packing and sortation system in the North-West of England. The project involved handling a diverse array of products such as cartons, cardboard envelopes, polybags, and jiffy bags. All of these items were online orders from a top E-Commerce retailer and were to be processed by 120 operators at a staggering rate of 7500 items per hour on a 24-hour shift basis.
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 in dispatching items and occasional damage. After consulting with multiple solutions providers, the client selected CSL as their preferred supplier.
To meet this challenge, CSL designed a system that featured eight product packing lanes, each outfitted with 15 packing benches. Packed products from each of these lanes were 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 of +2500mm. This arrangement allowed for operator movement beneath the system, facilitating an efficient 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 destination 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.
Two desktop PCs with Scada operator interfaces monitored the entire system, allowing operators to start and stop the system remotely, as well as enable and disable divert chute positions in real time.
To maintain operator access to the main fire exit doors in the building’s unique location, CSL designed and installed two bespoke access platforms.
The installation, testing, and commissioning of the entire system were accomplished within a 19-week period, underlining CSL’s commitment to efficiency and customer satisfaction.
