Optimizing Empty Case Replenishment with Hytrol Zero-Pressure Accumulation Conveyor and Itoh 90-Degree Transfers
A major food and beverage distributor in South Carolina successfully optimized its empty case replenishment process by automating it with a Hytrol zero-pressure accumulation conveyor and Itoh 90-degree transfers.
By integrating cutting-edge automation technology, the distributor streamlined operations across five drop filler lanes, improving overall productivity and reducing operator involvement, while enhancing space utilization.
Industry: Major Food and Beverage Distributor in South Carolina
Challenge: Empty case replenishment process, currently being handled manually, needed to be automated to 5 drop filler lanes.
Solution: Fully automated process with zero-pressure handling and sorting of empty cases.
Result: Increased empty case replenishment by 200%, eliminated manual labor, saved over 5 feet of valuable floor space.
Equipment: Hytrol E24EZ Zero-Pressure Accumulation Conveyor and Itoh Denki F-RAT NX75 90-Degree Transfers
Challenge: Create a more efficient, automated process for empty case replenishment.
A food and beverage distributor customer in South Carolina had an ongoing challenge with replenishing empty cases to 5 drop filler lanes. The previous process was manual, demanded too much floor space, it was time consuming with dedicated labor, and overall highly inefficient. They needed a more efficient way to execute the case replenishment process.
Solution: Integrated fully automated process with Accumulation Conveyor and 90-Degree Transfers.
AEC material handling specialist and engineer, Brian Hester, solved this challenge by implementing a combination of Hytrol E24EZ zero-pressure accumulation conveyor and Itoh Denki F-RAT NX75 90-degree transfers. Efficiently providing zero pressure handling and sorting of empty cases without operator intervention.
Hytrol E24EZ conveyor operates quietly and is highly flexible. And because the drive train is distributed along the length of the conveyor, it can achieve multiple speeds and directions, and even start or stop within individual sections. What’s more, the Itoh Denki flat right angle transfer modules use three motorized conveyor rollers within each unit to allow forward, backward, left, or right movement.
Result: Increased empty case replenishment by 200%.
This solution eliminated manual labor, saved over five feet of valuable floor space, and led to a 200% increase in replenishment efficiency.
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Fully automated process
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Zero operator involvement
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Saved over 5’ of much needed floor space
Brian Hester, Engineer and Material Handling Specialist
Brian Hester has been creating integrated material handling and storage solutions for over 20 years. His mission is to use his engineering background and extensive knowledge base of a wide variety of products to produce custom solutions that solve customer’s needs.
Brian specializes in packaging line integration, sortation and accumulation conveyor systems, distribution center conveyor systems, mobile aisle pallet rack systems, automatic storage and retrieval systems (ASRS), ergonomic lift and positioning equipment, heavy material lifts for floor-to-floor applications and mezzanines, modular offices and safety guarding (both custom and standard), and he loves big projects!