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High-Speed Product Sorter Conveyor System for Footwear Supplier

High-Speed Product Sorter Conveyor System for Footwear Supplier

Jan 6, 2023

Case Studies

High-Speed Product Sorter Conveyor System 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. This needed to support a pick process spread over a three-level warehouse that used thirty 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. This meant the sortation solution needed to keep up with this extremely quick rate. No pressure then… 

Identifying the best components for the conveyor system

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

The conveyor system solution

We installed barcode readers into areas that could identify the individual boxes in the conveyor system. They did this by looking up the product and matching it to the relevant order. This scan result then instructed the system on where to send each shoebox to. 

We decided to create two sorters. The first sorter having sixty-six destination lanes and the other thirty-six.  

These sorters have enabled our client to automatically sort up to 3,600 individual shoe boxes per hour. This gets them safely to 102 locations. There is zero manual intervention or product handling from staff.

This is a staggering cost and labour saving vs manual sortation methods and is a prime example of what a conveyor system can achieve. 

 

Need to sort products in a better or faster way?

PJP can offer a huge range of product sortation options as part of our conveyor system solutions, please contact us for more information. 

Product sortation conveyor system for shoe boxes
F-RAT Transfer units on large conveyor system
Footwear off to its destination on conveyor system

Automated Solution for Cosmetics Supplier

Automated Solution for Cosmetics Supplier

Jan 6, 2023

Case Studies

Automated Solution for Cosmetics Supplier

The requirement

A leading cosmetics supplier required a warehouse automation solution. It particularly needed to weigh and measure each of their parcels and incorporate the resulting information onto a printed carrier label. The resulting solution would be an automated despatch process.

To achieve this, PJP would need to create what is usually referred to as a DWS (Dimensioning Weighing and Scanning) System.

 

The design

With the brief established, PJP designed and constructed an automated system to do the following:

  1. Drive boxed orders to a weigh scale conveyor and scan a 2D barcode.
  2. Match the label data from the client database to the correct order.
  3. Our DWS unit should then automatically take the weight and all dimensions of the parcel. It should output this data to our Programmable Logic Controller (PLC).
  4. Once the parcel arrives at the print and apply machine, it scans the barcode and produces a label containing the shipping address, dimensions & weight.
  5. Automatically apply the label to the parcel.
  6. Dispatch the order to the relevant carrier for delivery.

The system includes a reject lane to eject any parcels not expected at the DWS which allows the despatch line to run continuously.  

Just one of many warehouse automation options

Our DWS solutions can handle a huge range of product sizes from the very small to the massive. DWS is a proud offering within our warehouse automation portfolio which facilitates fully automated, reliable processes that are tailored to your requirements.

Our DWS options can interface with your in-house systems whether they are Enterprise Resource Planning (ERP) or third-party Warehouse Management Systems (WMS).

You can read more about DWS (also known as volumetric data units) in this blog we dedicated to them.

 

Want to talk to a human?

Contact us to discuss your warehouse automation requirements, whatever they may be. We look forward to having an open and honest discussion with you!

Warehouse automation | Automated despatch process
Warehouse automation | Label print and apply machine
Warehouse Automation | A box is routed to its particular destination

Helping The Range Load up Lorries Quickly

Helping The Range Load up Lorries Quickly

Jan 6, 2023

Case Studies

Helping The Range Load up Lorries Quickly

This is a superb example of a Zero Line Pressure Conveyor System that we’ve introduced to one of the UK’s major retailers. It keeps everything moving safely and on time. 

From packing benches to loading bays

PJP Conveyors have designed, built and installed a Zero Line Pressure (ZLP) mild-steel conveyor system for The Range.

Line-shaft driven rollers and a 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. 90-degree F-RAT transfer units divert boxes accordingly and ensure the right parcel gets to the correct lorry.

ZLP systems protect people, products & the planet

If ‘pressure’ were to build up anywhere on this system, it could cause product damage or cause health and safety hazards.

ZLP systems ensures products don’t touch each other by creating a buffer between each one. Using sensors, this system keeps each item in a specific ‘zone’  at all times to stop bottlenecks (or pressure) occurring. Nothing moves along the line until the sytem confirms its next zone is clear. This creates a very smooth journey where packages reach their destination in pristine condition. 

The drives don’t constantly run, but constantly stop and start as needed. This means the system uses energy very efficiently. Another reason why this type of system is a great choice!

Zero Line Pressure Conveyor System at The Range
Curved section of zero Line pressure conveyor system
Straight section of ZLP system

Inspired to find out more?

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