Verizon Billing DC Gets Automated with Optimized Conveyor System Redesign

Challenge: Expansion Drives the Need for Increased Efficiency & Speed

“The original system that Verizon had from another supplier did not perform as expected. It was not capable of merging the multiple bill printing lines into the main takeaway conveyor,” Lonon says.

The conveyor they originally had taking the mail totes from the second to the first floor was also not performing as desired, so Verizon looked to AEC to provide a cost-effective solution. AEC removed every piece of the original conveyor and did a complete rebuild. Lonon handled the consulting, engineering, and project management for what would be a turnkey project.

Solution: Increased Control Over Merge Points with Hytrol 190-E24EZ Zero Pressure Accumulation Conveyor

“They needed a solution more well-suited for their operation,” Lonon explains.

To solve Verizon’s challenges, AEC installed Hytrol 190-E24EZ zero pressure accumulation conveyor along with Hytrol ARB merge belt at the main trunk line. The zero-pressure accumulation conveyor meant easier control of the merge points, and that both sides of the operation were able to use one conveyor feeding into a Ryson Spiral Conveyor.

The Hytrol conveyor was the best solution in this scenario because employees who worked close by noted the equipment is safer and is, importantly, quieter than other systems. What’s more, the Hytrol conveyor provides great flexibility. This came in handy most recently when Verizon upgraded their bill printing equipment, which necessitated a new conveyor layout provided and implemented by AEC.

Going Through the Roof – Literally – with Ryson Spiral Conveyor

Interestingly, because of doorway restrictions, AEC had to temporarily remove the roof to install the Ryson Spiral Conveyor. You might wonder why Verizon and AEC made such a decision, but the reasons for choosing a spiral conveyor were simple: A vertical lift module couldn’t provide adequate throughput rates, and there wasn’t enough space for a decline conveyor. And because the spiral ships fully assembled, the roof was the only way in.

Although the situation created some challenges, AEC and Verizon agreed it was a better option than knocking out a block wall.

“It was the best option we had,” Lonon recalls. “Ryson told me we were the first to install one of their spirals through a roof,” he says.

Hytrol PLC Provides Smart Automation

Another system upgrade for Verizon was a programmable logic controller (PLC) to automate the operation. Previously, the gravity system simply relied on, well, gravity. As a result, it was not unusual for totes to end up crashing onto the floor if there weren’t enough employees working at the end of the line.