How Hytrol Gapper Conveyors and Spantech Power Face Plow Created Consistent Product Flow in High-Volume Production
In warehouse facilities and distribution centers handling thousands of products daily, high-volume operations demand precision and efficiency at every step – and merging two conveyor lanes into one line while maintaining proper product spacing is no small feat.
When a global leader in tool manufacturing faced this challenge, they turned to Advanced Equipment Company (AEC) for an innovative solution. By leveraging the precision of Hytrol Gapper conveyors and the versatility of a Spantech Power Face Plow, material handling expert Charlie Williamson delivered a system that streamlined their operations and boosted throughput.
Industry: Large global tool manufacturer in North Carolina.
Challenge: Merging two conveyor lanes into one with precision handling.
Solution: Creating consistent gaps between the products and pushing them into one line with a plow.
Equipment: Hytrol Gapper Conveyor and Spantech Power Face Plow
Result: A seamless conveyor system merging two lanes into one with precise spacing, boosting throughput and minimizing downtime.
Challenge: Synchronizing Two Lanes into One
For high-volume production facilities, handling multiple product lanes is often essential to prevent bottlenecks during sorting, picking, and packing. However, as products move toward downstream processes – such as scanning, labeling, or palletizing – they frequently need to merge into a single line.
Our client, a global leader in tool manufacturing, faced this challenge in their facility. They needed a system capable of seamlessly merging two conveyor lanes into one while maintaining precise product spacing. The solution also needed to accommodate a variety of product sizes and weights without compromising efficiency or reliability.
Solution: Hytrol Gapper Conveyors and Spantech Power Face Plow
Charlie Williamson designed a system tailored to the customer’s needs using Hytrol Gapper Conveyors to manage product spacing and Spantech Power Face Plow to guide products into a single lane.
Hytrol Gapper Conveyors
Hytrol Gapper Conveyors create consistent spacing between products; a critical feature for downstream processes. Equipped with variable-speed belts and precision controls, these conveyors dynamically adjust gaps between items, ensuring smooth transitions through the merge point.
Hytrol gapper conveyors are known for their durability and low maintenance requirements, making them ideal for high-demand environments. Their modular construction also allowed seamless integration into the customer’s existing conveyor system.
Spantech Power Face Plow
The Spantech Power Face Plow is a versatile tool for managing product flow. Its plastic chain-link belt design minimizes friction and reduces product wear.
In this system, the Power Face Plow precisely redirected products from one conveyor lane to the primary lane. Where a standard plow would create friction and disrupt product spacing, the belt speed on the Power Face Plow was synchronized with the output of the gapper conveyors. This ensured proper alignment and product spacing as items moved toward downstream processes.
Result: Increased Throughput and Minimized Downtime
This innovative system, designed by Charlie Williamson, exceeded the customer’s expectations. It reliably merges two lanes into one while maintaining consistent spacing, reducing the risk of jams or misaligned products.
The result is increased throughput and minimized downtime, even during the manufacturer’s busiest production cycles. The combination of Hytrol Gapper conveyors and the Spantech Power Face Plow demonstrates how AEC leverages cutting-edge technology and expert design to optimize material handling operations.
How can seamless lane merging transform your throughput and efficiency?
Seamless lane merging transforms your throughput and efficiency by streamlining product flow, reducing the risk of jams, and maintaining precise spacing for downstream processes. This not only optimizes productivity but also minimizes downtime, ensuring your facility runs at peak performance even during the busiest production cycles.
At AEC, we specialize in delivering cutting-edge material handling solutions designed to meet the demands of high-volume operations. Whether you need to streamline conveyor systems, optimize throughput, or eliminate bottlenecks, our team of experts brings the experience and ingenuity to tackle even the most complex challenges.
Let us help you unlock your facility’s full potential – reach out today to discover how we can drive measurable results for your business.
Charlie Williamson, Special Accounts Engineer
Since 1988, Charlie Williamson has been a conveyor systems expert, with decades of experience in manufacturing processes, distribution centers, robotics, and packaging equipment integration.
His passion? Solving problems hands-on. Whether it’s boosting efficiency or streamlining a system, he takes pride in knowing that each business he helps is left better than before. If there’s a material handling challenge, Charlie’s expertise ensures it’s handled with precision and care, leaving a lasting impact on every project.
Written by AEC Sales Coordinator, Josh Hamrick.
