Equipment Report: Smarter sortation
In a competitive environment, it's not necessarily about moving products faster, it's about moving them smarter.
By Lorie King Rogers, Associate Editor -- Modern Materials Handling, 10/1/2009
The economy has packed a painful punch to all aspects of the materials handling industry recently. Sortation systems included. So what's the impact? What's happened over the last year? What's new in sortation, and where is the science of sortation headed?
"Over the last year, there haven't been many new changes in our industry," says Gregg Vandenbosch, global product manager for Dematic (616-931-6600, www.dematic.us). "What we are seeing is that end users are trying to squeeze as much out of their sortation systems as possible. They're looking for ways to get more out of their existing systems and looking for ways to run them smarter."
That's always a sound business strategy, especially in the world of sortation, since it's a fairly mature industry. While the past year didn't deliver revolutionary advancements like the introduction of motorized conveyor, the pop-up wheel diverters of the 1970s, or the shoe sorters of the 1980s, sortation has experienced some enhancements.
Going green
Driven by external economic and environmental forces, and internal industry competition, sortation is evolving into a brighter shade of green. Sortation solution providers and end users alike are jumping on the green bandwagon to reduce carbon footprints.
"Using a precision bearing, a low-friction rail cuts belt friction and cuts belt pull," says Del Deur, director of product development for TGW-Ermanco (231-798-4547, www.tgw-ermanco.com). "As a result, we're able to do the exact same amount of work using less energy. We have measurable results that prove we use 12.5% less energy now to do the same job as we did back in 1998."
Saving energy is a good thing, so is saving money. Deur also points out that not only does the low-friction rail save on energy expenses, it saves wear and tear on the equipment, which naturally translates to lower repair bills and lower replacement costs for sortation and conveyor systems.
Another way to achieve reduced energy consumption is to shift from linear induction motors to linear synchronous motors, says Rusty Matthews, sortation product manager for Intelligrated (513-701-7300, www.intelligrated.com). "Because they're more efficient, synchronous motors consume about 60% to 70% of the electricity needed to run the linear motors. The amount of savings will obviously depend on the amount of usage, but a company could save anywhere from $10,000 to $40,000 a year on energy expenses."
As the low-friction rail and synchronous motors illustrate, changes in hardware can contribute to a company's green bottom line. So can changes in software.
"Our company is seeing a lot of requests for us to change out old control software," says John Sarinick, vice president and division manager for Beumer (732-560-8222, www.beumer.com). "The mechanical part of the sortation system is still in place, but installing updated control software provides a more modern tool for running an efficient business."
Integrated process solutions
Companies are becoming increasingly savvy about applying technology to their processes. And, since software is the brain that controls the movement throughout the distribution center, utilizing the latest state-of-the-art software can enable your operation to run smarter.
For example, control software can optimize gapping. Gapping is the space between products on a conveyor belt. The goal is to reduce the gap between the items to increase throughput. The result is more items being processed in the same amount of time while the system runs at the same speed. The smaller the gap, the higher the rate of throughput, even with no other changes.
Control software, combined with sensors on the sortation equipment, can shrink a gap of 18 inches down to 6 inches or less and keep products moving as quickly and efficiently as possible. The sensor identifies the gap; the software controls the speed of the sortation sections, adjusting the pace for optimal performance. Dematic's Vandenbosch explains that a high-performance gapping device can be retrofitted into an existing facility to improve outcome.
Sometimes control software slows down the system. Just as with controls and timers on lighting and heating systems, powering up in peak times and powering down during slow times saves energy. That is also true with sortation systems.
"Applying variable speed drives to sortation systems is a power saver," explains Vandenbosch. "If a system is running, it's consuming power. When you decrease the speed, you decrease the power needed to run it." So it makes sense to slow the system when an opportunity presents itself. This strategy has a positive impact on power usage and can extend the system's life. Slowing down and speeding up is easier on the equipment than running full tilt all the time.
Software can control movement, and it also tells your company when there's a jam. A well-designed equipment control system can gather important information, provide valuable reporting statistics, and identify and diagnose systemic problems, which all lead to running a smarter, smoother, more productive and profitable operation.
On-site audits
How does a company sort out its sortation needs? Sortation solution providers are always on the lookout for ways to help customers run faster, smarter and leaner. One way this is happening is through on-site audits and fact-finding missions. These facility visits enable the provider to see the equipment in action, see how it's functioning and identify areas of potential performance improvements.
"Sortation doesn't add value to product," says TGW-Ermanco's Deur. "So the more we can do to help our customers achieve their goals of lowering the cost of goods going out the door, the better."
Intelligrated's Matthews points out the tremendous responsibility that materials handling systems providers have to customers. "The key to it all is that what we do has a really good or really bad impact on the companies we work with. So we're spending more time evaluating components, developing preventive maintenance programs, and looking for ways to reduce cost."
While some sortation solutions providers have reported a recent increase in interest from end users about the possibility of investing in new systems, the overwhelming current trend is to stay the course. "In this economy there isn't a lot of money for brand new systems," says Beumer's Sarinick, "so companies are upgrading old systems to get through the tough time. These upgrades are bridges between now and the future and buy time for a company until the economy turns around."
The specific sortation technology depends on the products your company handles, but the overall message applies to any company handling product: High-speed sortation can affect a company's top and bottom line.
"No matter what you're running, you have to have a capital plan for automation that meets your needs today and a few years out," says Tony Barr, Beumer's vice president of marketing and business development. "Put in a system that will help you address the bottom line—improve cost structure, take out direct labor, increase efficiency, and facilitate growth. But make sure the automation is and flexible enough to help your company drive critical process breakthroughs like cutting time to consumer. For example, if it's currently taking two days to get finished goods off the lines and to the end user, a new sortation system might reduce those 24 hours to 12 or six hours. High-speed unit sortation system can drive process breakthrough and sharpen a company's edge, capturing top line growth."
Sorting out the future
Contributing factors like the economy, labor and energy will continue to drive market trends. When industry's pain points shift, the focus shifts, and flexibility is important. For example, opt for a belt conveyor that can move diverse items, items that were once considered unconveyable. This will give your company the ability to handle mixed orders and be ready for new business.
If you have a narrow belt sorter, you can insert divert modules as you add shipping lanes. Make sure your order sorter is long enough to accommodate future growth and expansion. You may not be using the entire length right now, but you can add divert modules down the road as you grow.
"Companies not only have to think about their current situation and cost structure, but also in terms of how to position themselves to come out of the dark tunnel along with everyone else," says Barr. "Today's decisions position us to break out of gate and go after exciting growth after things turn around."
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