Intelligent conveyor solution optimises returns process
Task
Implementation of a compact buffer zone in returns management
CDs, games, books, etc. After Christmas, the volume of returns skyrockets – and with it, the pressure on intralogistics. In the returns centre of a logistics service provider, employees are under immense pressure during this time transferring returned items to the returns process. Following a visual inspection, the products are placed in small load carriers (SLC) on a circulation system, which then transports them to the returns warehouse.
This resulted in a recurring problem: Employees often had to wait for a free storage space. At the same time, empty SLCs regularly passed by during the visual inspection. The system was pushed to its limits at peak times. The backlog grew, and productivity decreased.
To achieve 100% capacity utilisation, the logistics service provider looked for a conveyor technology provider. It opted for mk because the experts were able to implement a space-saving and uncomplicated conveyor solution into the existing system – without any modifications.
Solution from mk
Automatic feeding station on three levels with buffer function
To increase the utilisation of the SLC circulation system, two feeding stations were constructed. These stations make it possible to buffer items and automatically feed them into the circulation system. As a result, employees become more productive, and the system is utilised to its full capacity.
The new stations are integrated into the existing system in a space-saving manner. To make this possible, three GUF-P 2000 belt conveyors are positioned one above the other. Their felt belts ensure gentle and stable transport of the delicate items.
The buffering on three levels works as follows: Each belt conveyor is divided into two sections. In the first section, there is a short infeed conveyor on which employees place the items – heavy products at the bottom for ergonomic reasons, lighter ones further up. With the help of light barriers, the infeed conveyors then automatically forward the items to the next belt conveyor, which, with a length of 3.5 metres, offers sufficient storage space.
The solution boasts one special feature –the belt conveyors are connected to each other via a machine frame that automatically swivels up and down. This allows the system to transfer the items from the three buffer levels at the same discharge height to a KGF-P 2040 curved belt conveyor from mk. This forwards the products to an existing conveyor, which transfers them to the SLCs in the circulation system via a tilting function.
Through a well thought-out combination of standard components and individual adjustments, an efficient transport solution was integrated into the existing system. mk was able to quickly assemble the buffer system from standard belt conveyors using the modular principle. However, a modification was required for the curved belt conveyor. The experts relocated the drive to allow the new conveyor to be positioned above the existing circulation system in a space-saving manner without any modifications.
To ensure the safety of the employees, mk has equipped the buffer system and three conveyors with a protective enclosure. The feed side is also covered with a sheet metal cover.
Customer benefits
- Increased productivity: The new conveyor solution with buffer function increases the utilisation of the intralogistics system and the productivity of employees.
- Efficiency in tight spaces: Belt conveyors on three levels enable space-saving buffering of items.
- Fast integration: The combination of standard components and individual adaptations allows integration of the new conveyor technology without any modifications to the existing system.
Products used
> GUF-P 2000 belt conveyor
> KGF-P 2040 curved belt conveyor
