Enhancing Product Flow with Intelligent Solutions
Implementing a high-density, 53-zone intelligent accumulation system to eliminate production gridlock with only two days of downtime.
Optimizing medical supply flow through intelligent automation.
When Halyard Health – a global leader in surgical and infection-prevention solutions – needed to overhaul the product flow at their Lexington facility, they required a system as precise as the medical supplies they manufacture. Handling critical items like sterilization wraps and surgical gowns requires a delicate balance of high volume and gentle touch.
Advanced Equipment Company (AEC) leveraged its deep expertise in high-capacity distribution to eliminate bottlenecks and replace manual handling with an intelligent, self-managing conveyor network.
Challenge: Eliminating the gridlock in high-volume production.
Halyard was struggling with a “stop-and-go” production environment caused by an outdated conveyor layout that couldn’t handle surge volumes. Manual intervention was frequently required to clear jams and manage product merging, which led to decreased throughput and potential product damage.
“The facility needed a way to intelligently buffer product between manufacturing and shipping without requiring constant operator oversight or complex, centralized PLC programming,” notes the AEC project team.
Solution: Implementing a self-aware accumulation network.
AEC material handling specialists introduced a sophisticated Hytrol IntelliVeyor™ system, utilizing decentralized 24V DC logic to give the conveyor “sight.” This allowed the line to automatically adjust speeds and create gaps for seamless merging without human intervention.
“By installing smart accumulation zones, AEC created a system that holds product in place during downstream delays and automatically releases it when the path is clear, ensuring a constant, damage-free flow to the loading docks,” explains AEC engineering lead.
Results: Precision performance with zero manual intervention.
The integration of intelligent accumulation transformed Halyard’s Lexington operations into a synchronized, low-maintenance environment. With only two days of downtime, Halyard was able to bring their entire operation up to speed. The new system, which spans 53 zones, is much more reliable and will require substantially less maintenance while significantly reducing the facility’s energy footprint.
“With the ‘gridlock’ removed, Halyard can now focus on their primary mission of medical innovation, backed by a material handling system that performs perfectly under pressure,” says AEC account manager.
Results at a glance.
- Autonomous Flow Control: Smart logic eliminates manual merging and operator intervention.
- Rapid Deployment: Full operation restored with only two days of downtime.
- Extensive Scalability: 53 intelligent zones providing high-density accumulation.
- Damage-Free Handling: Zero-pressure accumulation protects sensitive medical packaging.
- On-Demand Energy Efficiency: 24V DC zones power down automatically when the line is empty.
- Simplified Maintenance: Modular “plug-and-play” components reduce facility downtime.
See the system in action!
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