Automated barrier doors protect employees at shipping facility

High-cycle doors prevent workers from entering the automated storage and retrieval system.

By ·

Virginia-based Rubbermaid Commercial Products (RCP) serves markets worldwide including food services, sanitary maintenance, waste handling, material transport and safety products. In 2012, the company added a state-of-the-art automated shipping facility to its existing Winchester, Va., plant.

A conveyor system and 56 case-pick stations are integrated into the automated storage and retrieval system (AS/RS). Case-pick operations are on an elevated mezzanine structure that interfaces with the AS/RS, which deposits full pallets to pick stations. By installing a series of high-speed, high-cycle barrier doors, the company protected workers from fall hazards and moving machinery while maintaining productivity.

The new facility started round-the-clock operations in January 2013, sorting orders for customers worldwide. Three different types of physical barriers were considered to prevent the 1,200 workers in the plant from accidentally entering the AS/RS. An option similar to a parking gate arm was least expensive, but would serve more as a visual reminder than a physical barrier. A guillotine-style safety gate provided a physical barrier, but was not designed to withstand the expected open/close cycles of the application without substantial maintenance and downtime.

The third option was a high-speed, high-cycle barrier door (Frommelt Safety, with a roll-up design to minimize its footprint. The doors are integrated with the controls of the carton sortation system and are automatically operated by a programmable logic controller (PLC). To prevent injury during closing, the doors feature soft bottom edges and gravity-down operation. To minimize maintenance requirements, the doors were designed to withstand millions of cycles, have a 500 pound-rated, tear-out strength on their retention balls, and contain a fully sealed motor assembly.

“The doors have been in operation for several months and are performing exactly as advertised,” says John Elliott, senior distribution operations engineer for RCP. “The doors have provided a great degree of safety and operator labor efficiency for the application.”

About the Author

Josh Bond, Senior Editor
Josh Bond is Senior Editor for Modern, and was formerly Modern’s lift truck columnist and associate editor. He has a degree in Journalism from Keene State College and has studied business management at Franklin Pierce University.

Subscribe to Modern Materials Handling Magazine!

Subscribe today. It's FREE!
Find out what the world’s most innovative companies are doing to improve productivity in their plants and distribution centers.
Start your FREE subscription today!

Latest Whitepaper
Totes keep produce fresh from field to store
A two-part reusable plastic tote features a frame that cradles produce in a recyclable, replaceable sleeve.
Download Today!
From the December 2017 Modern Materials Handling Issue
Confronting an aging materials handling system and new channels of business with new customer expectations, Rocky Brands installed a put-to-light and sortation system to ramp up fulfillment.
The Big Picture: Navigation Gets a Reboot for Automatic Vehicles
Top 20 3PL Warehouses 2017: Growth amid change
View More From this Issue
Subscribe to Our Email Newsletter
Sign up today to receive our FREE, weekly email newsletter!
Latest Webcast
The State of the DC Voice Market
A lot has changed in the last 10 years, especially in voice technology. This webinar will cover the state of the voice market, review two leading voice solutions and help you gain a better understanding of the options and capabilities available today.
Register Today!
System Report: Rocky Brands Sees the Light
Confronting an aging materials handling system and new channels of business with new customer...
Top 20 industrial lift truck suppliers, 2017
The top lift truck suppliers list is changing with industry acquisitions causing a dramatic...

Lodge Manufacturing: Distribution Cast in Iron
In a new facility, iPhones and a new WMS allowed cookware manufacturer Lodge to double its business...
Rochester Drug Cooperative: Robots ready for work
It’s still early stages, but Rochester Drug Cooperative is proving that mobile robotic piece...