Adding almost 100,000 square feet of space to a warehouse necessitates a total rehaul of how product is distributed, as prescription glasses and sunglasses retailer Luxottica discovered.

Its Atlanta facility, the largest of its five North American distribution centers, increased space from 87,200 square feet to 179,700 square feet in early 2006. Pedro Carreras, associate vice president of the Americas, says Luxottica turned to conveyors (Intelligrated, 513-701-7300, www.intelligrated.com) to move and ship the Ray-Ban, Oakley, Burberry and Chanel frames and sunglasses.

Before the expansion, a very limited conveyor system was in place in the facility, says Carreras. The extra square footage necessitated some kind of product movement equipment, including accumulation conveyors, sliding shoe sorters, a cross-belt sorter and bulk belt conveyor.

As the world's leading designer, manufacturer and distributor of prescription glasses and sunglasses, there's always the chance Luxottica may need to expand further. “The system is serving its purpose as of today,” Carreras says. “As our growth continues, we have the ability to add more.”

By installing an extensive conveyor system, few additional personnel were needed. And those who were working with the system enjoyed ergonomic benefits. With the old system, workers would have to pick up the packed box, turn around and place it on the shipping belt. Now the conveyor system is in line with the packing system, and workers never have to lift the box at any point, just push it.

Carreras praises the quietness of the solution. Instead of having a belt drive in the center that can get noisier with time, these conveyors place the drive to the side, so the rollers won't bow as much.