Very long transport routes for processing returns

Task

To process returns, a logistics service provider needs a very long, circulating belt conveyor. The returns are packed in standardised boxes and are to be conveyed in a circuit. The boxes are removed manually from a continuous conveyor belt, processed and put back on the conveyor belt. The organisation of the task can be chaotic, i.e. the boxes can have different orientations and can also be stacked on top of each other. A high mass flow rate of boxes is expected. On average, a box weighs around 10 to 30 kg. The noise generated by the system must be as low as possible so that the health of the workers is not affected and a pleasant working atmosphere is maintained. The belt conveyor should also be low-maintenance and as inexpensive as possible. 

Solution from mk

mk built a circulating conveying path made of modular belt conveyors to meet the customer's requirements. Modular belt chains are very robust and low-maintenance. If there are defects in the chain, individual modules can be replaced. In addition, the modular belt chain can generate high tensile forces thanks to the positive drive mechanism. Using wear strips to guide the chain means that lateral forces can be easily absorbed when parts are moved diagonally.

Several very long modular belt conveyors measuring up to 20 m per conveyor were combined into two circuits. The conveyors run relatively quickly at a speed of 30 m/min. Driven roller conveyors were used on the curves. If the load increases, the second circuit can be switched on manually. To do so, a swivelling timing belt conveyor is used as a switch. In order to keep the noise generated by the modular belt conveyors to a minimum, large wheels were used underneath the conveyors. The chain bags created by a modular belt gently glide over these. The conveyors on the operator side were also completely covered, which dampens noise and serves as a protective guard. In order to keep the costs for the system low, no automation was used, i.e. no tracking of the boxes and no allocation of the products to the boxes. The products themselves are tracked by the workers and sorted flexibly into the boxes.

Benefits for the customer

• Proven experience in order picking and intralogistics tasks
• Production of very long conveyor technology lines in a short time
• Cost-effective due to low level of automation
• Fast response time and good accessibility even in the event of difficulties
• Reliable customer support even after handover and commissioning

Products used

> Modular belt conveyor
> Roller conveyor