Advanced Pallet Conveyor Solution for Manufacturing Tunnel
Implementing a 335 foot “smart” tunnel to synchronize high speed manufacturing with high capacity warehousing.
Doubling capacity with a high performance conveyor tunnel.
Technimark, a global leader in turnkey injection molding, faced a critical logistical bottleneck at their Asheboro, North Carolina facility. To move finished product from manufacturing to the warehouse, the plant relied on a single 335 foot tunnel conveyor that had become a liability.
Advanced Equipment Company (AEC) was brought in to engineer a second tunnel system that would not only double capacity but replace outdated, high maintenance machinery with a streamlined, self managing solution.
Challenge: Overcoming the inefficiencies of maintenance intensive transport.
The existing tunnel conveyor was built with used equipment and outdated technology, utilizing clutches and sensing rollers that required constant repair. Because the plant operates at such high volumes, any conveyor downtime forced the company to transport product by truck: an expensive and inefficient alternative. Furthermore, the new tunnel design required the conveyor to navigate a unique 3 degree decline and a curve, posing a risk of product “coasting” or drifting between zones.
“Basically, the conveyor was wearing itself out by running constantly. When this conveyor has maintenance problems, it’s a major issue for the company. They can’t get the product from manufacturing to the warehouse,” says AEC Material Handling Specialist Scott Hartman.
Solution: Implementing a self aware, low complexity network.
AEC implemented the Hytrol 25CREZD with EZLogic Zoned Accumulation, spanning 67 five foot zones. To solve the decline issue without expensive braking systems, AEC and Hytrol utilized double gear reduction to prevent pallet drift. Instead of the maintenance heavy PLC controlled pivot carts used in the original tunnel, AEC engineered a simple gravity tapered roller section to handle the turn, significantly reducing the mechanical “fail points” of the system.
“This solution would not only be able to stand up to the vigorous workload but was also way less complex than the original system. Any zone can be configured for loading or unloading, and zones only run when needed,” explains Hartman.
Results: Simplified installation and 24/7 reliability.
By prioritizing simplicity over complexity, AEC delivered a system that was intuitive enough for the customer to install themselves in less than one week. The new system spanned about 335 feet of conveyor which equals 67 individual 5 foot zones of accumulation. The final installation requires significantly less electrical wiring and eliminates the need for a centralized PLC, resulting in a robust, low maintenance “highway” that ensures Technimark’s manufacturing never outpaces its distribution.
“This job was sold because of the reduction in complexity compared to what they used to have: it was kind of a no brainer for them. It was easy to put together, they had very little electrical wiring to get it up and running, and they could install it themselves,” says Hartman.
Results at a glance.
- Massive Scale: 335 feet of automated transport across 67 independent accumulation zones.
- Rapid Deployment: Full customer installation completed in less than one week.
- Smart Braking: Double gear reduction prevents 4,000 lb. loads from drifting on a 3 degree decline.
- Reduced Complexity: Eliminated the need for PLCs, pneumatic solenoids, and friction brakes.
- Energy Efficient: 24V DC logic ensures motors only run when product is moving.
- Low Maintenance: Replaced complex pivot carts with simple gravity tapered rollers.
See the system in action!
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