To most people, conveyor belts are nothing more than a system of pulleys and rollers that move items from one location to another along the production line. However, there’s a lot more to learn about these machines before adding them to your company.
Besides the fact that conveyor belts are useful in many other industries besides manufacturing plants (including construction sites, warehousing facilities, distribution centers, etc.), the systems are far more sophisticated than commonly thought. One of the most innovative technologies in modern conveyor belts is the introduction of a sortation system.
In this article, we shall introduce the role of a conveyor belt sortation system and highlight the top five considerations when picking one.
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What Are Conveyor Sortation Systems?
Conveyor sortation systems are special conveyor belt systems that automatically separate items into different routes and packing lines along the belt channel.
Sortation systems are one of the most innovative technologies in the belt conveyor industry. Manufacturing companies rely on these advanced machines to identify similar items from the same production batch, easing the inventory tracking process. Other industries, such as warehouses, use automated sorting conveyors to sort similar goods for easy storage or distribution.
The surging demand for conveyor belts is largely attributed to the emergence of conveyor sortation systems.
Many companies invest in automated sorting conveyors to minimize the reliance on human personnel at each dispensing point along the belt system. In turn, this reduces overheads while increasing revenue generation.
Besides reducing labor-related expenses, conveyor sortation systems also improve order accuracy. Installing this equipment can boost workplace productivity by minimizing downtime often caused by human error.
Factors to Consider When Choosing Conveyor Sortation Systems
- Mechanical Design
Conveyor sortation systems come in multiple designs. Common ones include:
- Strip Belt/Narrow Belt Systems – Made of several narrow belts that divert goods to different lanes, with a wheel fitted between each belt.
- Cross Belt Systems – Consist of sorters that divide items through small belted trays or containers.
- Tilt Tray Systems – These sorters feature trays linked to a chain, which tip to both sides to dump packages into chutes.
- Pop-Up Belt Systems – Also known as chain sorters, pop-up sorters sort items by pulling them onto angled spurs before dumping them to either side of the conveyor channel.
- Swivel Wheel/Roller Sorters – Designed to push packages on either side of the conveyor line using a roller that swivels to allow some items to pass and divert others.
- Product Characteristics
The nature of the items you intend to move along a conveyor line is critical when choosing a conveyor sortation system. Specific aspects to consider here include product size, weight, and shape.
Strive to match a sortation system with the products it’s designed to convey. This ensures smooth operation of the conveyor belt and minimizes accidents while operating these machines.
One best practice is to pick a versatile conveyor sortation system. These pieces of equipment provide flexibility in the event your business diversifies into other goods. They’re also more cost-effective than buying multiple sortation systems of different designs.
- Ideal Use Environment
What is the nature of your facility? Are you looking for a conveyor sortation system to add to your production line or to sort items as they head to the warehouse? As you shall find, there’s a conveyor sortation system designed for each scenario.
Check how the equipment is configured before procuring it. If you’re in doubt, inquire about the machine’s ideal use case from the manufacturer before installing it in your workplace.
A conveyor sortation’s intended application also impacts the installation process. Most machines have a specific number of packing and sorting stations to set up.
- Throughput Rate
Throughout rate, concerning conveyor sortation systems, refers to the total number of items the machine can sort per hour.
Automated sortation systems come with varied speeds. So, it’s important to project your company’s throughput needs before picking the right equipment. Insist on high-speed models if your facility consistently handles large volumes of packages.
Factors like seasonal demand variations and your budget also determine the best sortation system to invest in.
For instance, purchasing a high-speed conveyor sortation system makes little economic sense if your facility only records overwhelming demand a few weeks a year.
- Space Limitations
Like regular conveyor belts, automated sortation systems are quite bulky. While their size differs by design and configuration, reserving ample installation space before procuring the machines is prudent.
Assess both the vertical and linear floor space available. Specific conveyor sortation systems are easy to install as a loop, while others must be set up in a linear configuration.
Ultimately, choose a system that optimizes the available spatial space without compromising your facility’s operational efficiency.
The machine should never occupy the full room. Besides impeding access, filling a workspace with a conveyor sortation system poses safety hazards to your employees.
Summary
Sortation conveyors are sophisticated systems that must be approached with extreme caution.
For starters, always enlist professional services when installing conveyor sortation systems. It’s also prudent to handle these complex machines strictly following the manufacturer’s operational guidelines.
And if you ever suspect a glitch in your sortation conveyor system, it’s best to seek technical help immediately. Prompt intervention can help minimize operational downtimes and costly repairs associated with a malfunctioning system.
