Introduction to Automated Sorting and Packaging;

Advanced Conveyor Systems (ACS) is a leading provider of automated sorting and packaging solutions. We offer various conveyor-based systems designed to increase efficiency and productivity in manufacturing and distribution operations. Our sorting and packaging solutions are used in multiple industries, including food and beverage, pharmaceutical, automotive, and e-commerce.

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ACS provides complete turnkey solutions for automated sorting and packaging operations. We have the experience and expertise to help you select the right equipment for your application. Our systems are designed to work seamlessly with your existing process, ensuring smooth integration and optimal performance.

Whether you’re looking to improve efficiency, reduce labor costs, or simply keep up with the competition, ACS can provide a solution that fits your needs. Contact us today to learn more about our automated sorting and packaging solutions!

Benefits of Automated Sorting and Packaging;

There are many benefits to automated sorting and packaging, including:

1. Increased efficiency and productivity — Automated sorting and packaging can significantly increase the efficiency and productivity of your business. By automating the process of sorting and packaging items, you can free up your employees to focus on other tasks.

2. Reduced labor costs — Automated sorting and packaging can help to reduce labor costs associated with your business. You can save on labor costs by eliminating the need for manual sorting and packaging.

3. Improved product quality — Automated sorting and packaging can improve the overall quality of your products. You can improve your grade by ensuring that each product is adequately sorted and packaged.

4. Enhanced customer satisfaction — Automated sorting and packaging can help to enhance customer satisfaction. By providing customers with properly sorted and packaged products, you can improve their overall experience with your business.

Types of Advanced Conveyor Systems;

The term “advanced conveyor system” can mean different things to different people. Here, we’re going to explore some of the types of automated sorting and packaging systems available today.

• One type of advanced conveyor system is an automated sortation system. These systems use a variety of sensors and cameras to identify and sort products as they move along the conveyor belt. This can be used for various purposes, such as sorting products by size, shape, or color.
• Another type of advanced conveyor system is an automated packaging system. These systems use robots to pick up products from the conveyor belt and place them into boxes or other containers. This can be used to speed up the packaging process and improve accuracy.

There are also complete turnkey solutions that include both sorting and packaging systems. These solutions are often used in e-commerce applications where orders must be sorted and packaged for shipping.

How Advanced Conveyor Systems Work?

Advanced conveyor systems are computer-controlled conveyor belts that move items through a warehouse or distribution center quickly and efficiently. These systems use sensors to track the items on the conveyor belt and direct them to the correct sorting or packaging station. Advanced conveyor systems can sort and package items of all shapes and sizes and even handle delicate items such as eggs or wine bottles.

Conveyor systems have been used in warehouses and distribution centers for many years. Still, traditional conveyor belts need to improve their speed and ability to sort and package items accurately. Advanced conveyor systems overcome these limitations by using computer-controlled motors to move the conveyor belt at high speeds and using sensors to track the items on the belt and direct them to the correct station.

Advanced conveyor systems can sort and package a wide variety of items, including:

• Clothing

• Electronics

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• Food

• Furniture

• Toys

Tips for Maintaining Automated Sorting and Packaging Systems;

To keep automated sorting and packaging systems running smoothly, regularly checking and maintaining the equipment is essential. Here are some tips for maintaining these systems:

1. Check conveyor belts for rips, tears, or other damage. Replace or repair any damaged parts as needed.
2. Inspect the sensors and cameras that are used to sort items. Make sure they are clean and free of debris so that they can accurately detect and sort things.
3. Lubricate all moving parts on the conveyor system to keep them running smoothly.
4. Calibrate the weight scales that are used to measure items being sorted. This will ensure accurate readings and ensure things are correctly categorized.
5. Keep the area around the conveyor system clean and free of clutter. This will help prevent items from getting stuck or caught in the machinery.

Common Problems with Automated Sorting and Packaging Systems;

One common problem with automated sorting and packaging systems is that they can often malfunction, resulting in lost or damaged products. Sometimes, these systems may also need help to sort or package products, leading to customer dissatisfaction properly. Automated sorting and packaging systems can be expensive to maintain and operate, cutting a company’s profits.

Conclusion;

Automated sorting and packaging with advanced conveyor systems is a great way to provide efficient, reliable, and accurate sorting of products. Using sensors, barcodes, RFID tags, and other technologies to sort items offers higher accuracy and faster throughput than manual processes. With these systems’ increased efficiency, they are becoming increasingly popular in the manufacturing industry. Investing in an automated system can be well worth considering all of the benefits that come with it, such as improved productivity and cost savings!

Selecting the Right Sortation Conveyor Requires Both Insight and Foresight

A sortation conveyor system is an automated solution designed to efficiently organize and distribute items based on predetermined criteria such as destination, size, or weight. Often found in manufacturing plants, distribution centers, and e-commerce fulfillment centers, sortation conveyors are crucial in streamlining activity by rapidly segregating diverse items into specific categories, product groupings, destinations, packaging, etc. These systems enhance operational efficiency, reduce labor costs, minimize errors, and ultimately contribute to faster and more accurate order fulfillment, making them essential for industries reliant on timely and precise inventory management.

Selecting a sortation conveyor solution for your facility can involve a substantial investment in hardware and software that can also be expensive to reconfigure if your requirements change. To optimize your investment dollar, you’ll need to answer the following  5 questions. Be sure to define your current needs and any future expectations your team is considering.

1. Inventory Specs
2. Throughput
3. Space Availability
4. Application
5. Budget

With that background in place, let’s take a deeper look at each of the 5 criteria needed to configure your sortation conveyor solution.

1. What Are the Physical Attributes of the Products You Are Sorting?

Sortation conveyor designs cover a vast range of techniques and technologies. Suppose you are sorting a relatively consistent size of medium-weight products packaged in cardboard boxes. In that case, your options differ from sorting garments packaged in plastic bags or suspended from hangars. Size, shape, weight, and physical characteristics play a big role in the sortation conveyor best suited for your application. Product fragility plays a big part, too. A shoe or slot sorter might be ideal for electronics packaged in boxes that aren’t too weighty, whereas for sweaters packed in plastic, a tilt-tray sorter works very well. 

Another consideration is future needs. If your facility will be sorting the same products five years from now as it is today, you can be comfortable settling on one type of sorter. If your product mix changes regularly or will change in the future, consider specifying a system that allows your distribution center to handle different types of products flexibly. 

2. What is the Throughput Rate Your Facility Needs to Achieve?

The speed at which products in your facility move and need to be sorted is a major factor in the type of sortation system you select and the elements of the technology your facility needs to employ to achieve that sortation rate. Questions that need to be answered are:

• What is our usual throughput rate in units/minute, per hour, per shift?
• What is the variability of that rate? Are there waves of products, like when trucks are unloaded? Or seasonal variations? 
• Does my budget allow me to employ the fastest and most flexible system? The faster the sortation, the more expensive the system.

3. What Are My Space Limitations?

Different types of sortation conveyors require different amounts of floor space. The size of your warehouse and the available floor space may limit the selection of sortation conveyors you can use. Do you have vertical space available? Can the sortation systems be designed as a loop, or does it need to be linear with a number of branches coming off the main conveyor line?

4. What is the Application of the Sortation Conveyor?

A sortation system designed for sorting products being unloaded from trucks and headed for storage may be configured much differently than a sortation system separating items destined to ship to a multitude of retail stores. Again, size, weight, and variability of products are determining factors, as are how many sources/destinations have to be built into the system. Do packing stations or shipping stations need to be set up? All of these considerations impact the choice of sortation conveyor that best fits your application. 

5. And, Of Course, What is Your Budget?

Can you afford to employ the most elegant technological sortation solution… or do you even need it? Sortation systems can be very complex, employing sensors, programmable logic controllers (PLCs), mechanical devices for executing the sortation, and software that can feed data into your WCS or WMS. The level of automation required in your application will be a huge determinant of the cost of your sortation conveyor system.

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