Rapid Conveyor Solution to Help National Retailer Cope with Christmas

Rapid Conveyor Solution to Help National Retailer Cope with Christmas

Case Studies

Rapid Conveyor Solution to Help National Retailer Cope with Christmas

A Christmas disaster strikes

It wasn’t looking like it was going to be a great Christmas for this national retailer. Their existing conveyor was finally beyond economical repair due to its age and condition after having been used 7 days a week for 12 years. It was heavily relied on as it was the only method of staff getting bulky items safely between floors in the warehouse – including lots of potential Christmas presents.

Just as their sales were ramping up, their conveyor broke down. 

 

PJP to the rescue

The organisation rightly called on PJP Conveyors to assist. We understood how vital these conveyors were to operations, especially so close to a major trading period.

Our strategy to ensure continuous operations was to attempt a temporary repair to see them through the period until a new conveyor could be supplied. Much to the delight of the client, we were able to carry out the repair successfully to enable limited use of the existing conveyor.

A sustainable long term solution developed

Meanwhile, the rest of the PJP team pulled out all the stops to get a new conveyor designed, manufactured, delivered & installed in less than 6 weeks from original breakdown being reported!

We also managed to get all the associated electrical controls replaced and upgraded so that they met current safety standards.

Christmas miracles (available any time of the year)

This is the closest PJP and the client got to a Christmas miracle, because our quick thinking and speedy turnaround truly saved the client from a very sticky situation.

PJP can offer a huge range of conveyor solutions, please contact us for more information. 

Bespoke Conveyors for Plastic Extrusion Pipe-making

Bespoke Conveyors for Plastic Extrusion Pipe-making

Case Studies

Bespoke Conveyors for Plastic Extrusion Pipe-making

A catalogue of different pipe requirements

PJP recently supplied three bespoke off-feed conveyors for a major plastics extrusion company to facilitate their ability to make pipes for domestic and commercial settings. The system needed to take extrusion sections directly off the production line and deposit them into stillages.

The various demands of heating, drainage and plumbing require a multitude of different length pipes, therefore we needed to create a moveable end-stop to allow for different cut lengths of product.

The conveyor system was made from a robust mild steel construction and needed to be mobile to allow it to move between different production lines for maximum versatility and ROI for the customer.

Bespoke conveyors and electrical controls 

To complement the system, PJP also designed and built bespoke electrical controls to allow for speed adjustment and integration with the customer’s own extrusion line machinery.

The bespoke conveyors and electrical controls were designed and manufactured at PJP’s in-house facility in Nottingham. The system was delivered in an impressive 8 weeks from the order being placed.

Contact us to find out more. 

High-Speed Product Sorter for Footwear Supplier

High-Speed Product Sorter for Footwear Supplier

Case Studies

High-Speed Product Sorter for Footwear Supplier

A colossal conveyor challenge

PJP were tasked with the design, build, installation and commissioning of a high-speed sortation solution. This ended up being part of one of the largest conveyor systems we’ve ever supplied!

The remit was to sort shoe boxes into 102 destinations following a pick process spread over a three-level warehouse using 30 pickers. The pick process and transport conveyors (also supplied and installed by PJP) can output a shoe box at a rate of one per second so the sortation solution needed to keep up with this extremely quick rate. 

Identifying the best components

PJP compared many bi-directional product transfer units and, following various tests and consultations, we selected the Itoh Denki ‘F-Rat’ 24v transfer unit due to low noise, efficient transfer, high speed 24v technology and low maintenance. The units also allow product separation and even give a zero-line pressure feature for complete stability and accuracy which is essential when handling a huge range of box sizes at this speed: anything from 150mm x 150mm up to 600mm x 600mm.

The solution

We decided upon two sorters – one with 66 destinations and the other 36. Prior to the sorters we included a barcode reader to identify the box, look up the product, match it to the relevant order and then instruct the system on which lane to send each shoebox to. 

These sorters have enabled our client to automatically sort up to 3600 individual shoe boxes per hour and get them safely to 102 locations, with zero manual intervention or product handling from staff. Quite a staggering cost and labour saving vs manual sortation methods…. 

PJP can offer a huge range of product sortation solutions, please contact us for more information. 

PJP’s Solution to a Common Warehouse Challenge

PJP’s Solution to a Common Warehouse Challenge

Case Studies

PJP’s Solution to a Common Warehouse Challenge

A pet-food challenge

We were approached by a pet-food supplier to look at ways they could streamline their end of line / despatch process. Traditionally, it is this area – the critical order despatch process – that can be a bottleneck for many operations.

The specific challenge was to design a transport conveyor which could deliver totes of picked product to sixteen dedicated packing benches. It then needed to allow operators to pack the products into delivery cartons, apply a courier label and then send the completed order to a single despatch location. There could be no walking with, or lifting of, any product during the process.

Bespoke conveyor design on two-levels 

To achieve this, PJP designed a bespoke two-tier conveyor system that does the following:

  • The top tier delivers totes to packing bench positions using Zero-Line Pressure (ZLP) technology to ensure no collisions or finger traps occur during use – health & safety is a very important factor for us and our clients.
  • Specially designed packing benches (workstations) then allow operators to simply slide the tote onto their workstation and process it.
  • Once complete, operators use the lower tier by sliding the completed, boxed order onto a small decline belt, which automatically drives every box in the warehouse to the dedicated despatch point. This is achieved via an intelligent traffic light system with no interaction required from operators.

 

Space saving solution

Another part of the remit was to keep the footprint of the system as small as possible as space, like in any warehouse operation, is a very valuable commodity. The two-tier setup and twin lane approach gave maximum performance whilst keeping the footprint to a minimum.

Serious uplifts in productivity

Prior to this system being implemented, the client was achieving a completed order every 3-4 minutes. The new system allows them to achieve a throughput of one order every 10 seconds. All in all, a very attractive return on investment was achieved which eliminated manual lifting and walking from the process.

Challenge accepted and solution delivered!

Why not get in touch to tell about your warehouse challenges?

Helping The Range Load up Lorries Quickly

Helping The Range Load up Lorries Quickly

Case Studies

Helping The Range Load up Lorries Quickly

From packing benches to loading bays

PJP have designed and built a mild-steel conveyor system which is performing well at The Range. Line-shaft driven rollers and a Zero-Line Pressure (ZLP) system now take parcels of products efficiently around from packing benches to lorry loading bays. The parcels are individually separated and distributed straight to docked lorries via flexible conveyors using 90-degree F-RAT transfers which divert boxes accordingly and ensure the right parcel gets to the correct lorry.

Zero line pressure solution protects people & products

One of the advantages of using ZLP in this solution is that it ensures products don’t touch each other. So, there’s no ‘pressure’ building up anywhere which may cause product damage or cause health and safety hazards.

If you think that incorporating a ZLP conveyor solution may have similar benefits for your business, get in touch and we’d be delighted to help.