Span Tech, Author at Span Tech Conveyors

Guide To Automated Warehouse Systems

Posted on May 5, 2021September 22, 2023 by Span Tech

We are far beyond the labor-intensive manufacturing world of the past. Previously, the majority of your success was defined by the sheer size of your labor force. Today, more and more companies are utilizing automated warehouse systems to streamline production and increase efficiency. The changing of the guard happened alongside the advancement of technology and automation. Manufacturers began to harness these things for convenience’s sake and to gain a sizable edge over the competition.

To compete in today’s world of manufacturing, efficiency is essential to the process, and to this end, nothing helps to facilitate efficiency better than an automated warehouse. Keep reading to learn how warehouse automation works and how manufacturers can use automated warehouse systems to put themselves and their employees in a better position to be successful.

What Is Warehouse Automation?

Moving inventory into, within and out of warehouses and then delivering to customers with little-to-no human assistance is referred to as warehouse automation. Businesses that implement an automated warehouse system into their operations can neutralize labor-intensive assignments that involve manual data entry and analysis, as well as repetitive physical work.

A real-world example of automation in action is when a warehouse employee loads an autonomous mobile robot with heavy and cumbersome packages. The robot then moves the inventory from one end of the warehouse to the other, with the inventory’s final destination being the shipping zone.

During the transport of inventory, software records the movement of the supplies, keeping all records current. Consequently, the utilization of these robots helps to improve the speed, reliability, accuracy and frequency of this task.

An automated warehouse begins with a warehouse management system (WMS), data collection and inventory control. Despite having considerable upfront costs, the immediate and long-term benefits are well worth it.

By incorporating robotics and artificial intelligence (AI) integration onto the warehouse floor, you’ll reduce human error and improve overall operations. The incredible benefits and exciting future of warehouse automation know no bounds.

Automated Warehouse Systems

An automated warehouse system or automated storage and retrieval system (AS/RS) is a GTP technology that uses vehicles, carousels and cranes to efficiently move inventory throughout the warehouse to warehouse storage locations.

Conveyor Systems

One of the oldest automated warehouse technologies is conveyor systems. Simply put, conveyors move materials along assembly lines to different work stations such as sorting areas, packaging areas and shipping areas.

Voice Picking and Voice Tasking

This automated warehouse system requires employees known as pickers to use wireless headsets to communicate with taskers in order to coordinate picking tasks and movements. Voice picking infuses communication technology into a warehouse order picker’s routine.

Pick-To-Light Systems

This system utilizes barcodes and LED lights to help employees locate the necessary items to fulfill orders. Pick-to-light systems lessen human exertion by decreasing walking time and increasing productivity by helping to locate items faster.

Sortation Systems

This automated warehouse system can access the correct locations and the proper bins using different technologies that identify and separate items, directing them to pick zones, packing stations or returns processing.

Drones

Typically drones are used for inventory management. They’re equipped with barcode scanners to make inventory counts and alert the staff when items need to be restocked or are stored in the wrong location.

Collaborative Mobile Robots

These robots work side by side with humans to improve productivity and picking accuracy while guiding workers through the picking process.

Automated Distribution

Automated distribution includes all systems in place to create increased efficiency within a warehouse related to distribution.

Receiving

Mobile devices can be used to capture data from your warehouse receiving area quickly. Integrated software captures, processes and stores essential data that influences downstream and upstream automated workflows.

Returns

When dealing with returns, automated sorting systems in conjunction with equipment such as conveyors can automate the return process procedure. The system can sort products to return to stock shelves or put them away in storage areas.

Putaway

Putaway is the process of moving products from receiving to storage. Physical and digital warehouse process automation makes putaway more accurate and efficient. The automation can also help facilitate cross-docking.

Picking

Picking, when done manually, is the most expensive warehouse activity by far. Did you know that warehouse travel time accounts for as much as 50 percent of all working hours? GTP systems and autonomous mobile robots markedly increase the efficiency and speed of moving inventory.

Sorting

When you sort and consolidate warehouse inventory, it can be cumbersome, confusing and time-consuming. Fortunately, the automated sortation and AS/RS systems significantly improve quality control and inventory accuracy.

Replenishment

Automated inventory tracking triggers an automatic order request when an inventory item reaches a specific par level and flags it for approval. Automated replenishment helps prevent overstocking costs and inventory loss due to stealing or spoilage.

Packaging

The environmental ramifications for using packaging materials can be compounded when done without precision. Automated packing and cartonization systems use precise algorithms to determine the best way to package material with minimum waste.

Shipping

Automated shipping systems are comprehensively helpful with the use of printers, dimension sensors, scales, conveyors and software applications to choose available carriers. Additionally, the system estimates shipping rates and places labels onto packages for shipment.

What Are the Current Warehouse Automation Trends?

Here are the current automation trends that are beginning to surface in warehousing worldwide in an attempt to keep up with technological advances and growing demand.

Widespread Use of Robots

Robots cover their cost in about three to nine months; even small businesses with minimal budgets can invest in robots.

Mobile Robots AGV/AMR

Automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) are scalable and do not need two variations to the existing floor plan or the infrastructure of the warehouse.

Drones

Useful for shipping, delivery and scanning barcodes and RFID tags efficiently, operating in hard-to-reach locations.

Cobots

Cobots are specially designed to work with humans. Currently, cobots account for less than 5 percent of the robotics market, which is poised to rise to 30.2 percent in the coming years.

Upgrade Your Automated Warehouse System with the Help of Span Tech

Keeping up in today’s competitive world requires an edge, and Span Tech is poised to help you gain that competitive edge to make your warehouse even more productive! Span Tech has a bevy of professionals ready to help you strike the coveted perfect balance of warehouse supply and demand with an innovative implementation strategy and cutting-edge automated technology. Contact us to learn more about implementing an automated warehouse system into your business today!

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What is the OutRunner Spiral?

Posted on April 29, 2021April 29, 2021 by Span Tech

For employees working in a manufacturing plant or other factories, safety and efficient automation are strongly prioritized. From food and beverage production to e-commerce, items need to move rapidly and undergo rigorous quality control to ensure orders are successfully fulfilled. Fortunately, conveyor systems can cut down on manual tasks and streamline the productivity of assembly lines worldwide. That’s why we build innovative and responsive standard and specialty conveyor systems, including our patented OutRunner Spiral.

Span Tech’s OutRunner Spiral conveyor uses a unique drive system which has many advantages for spiral designs. This changing elevation conveyor system drives each tier of the spiral conveyor, which distributes the overall loading throughout many points and reduces the amount of “pull” needed at any single location. Additionally, OutRunner Spiral conveyors are somewhat similar to drum-style spirals which are very common in the industry. However, a huge flaw with drum spiral designs is the need to have a pulling element after the spiral’s last tier. If the drum ever stops and the pulling element is allowed to continue to run, the entire conveyor chain will “fold up” against the drum. This is quite a dramatic event and certainly unwanted in any situation.

Why Should Companies Use an OutRunner Spiral Conveyor?

If you’d like to update the conveyor system in your facility, there are three main reasons to include an OutRunner Spiral in your production flow:

1. The OutRunner Spiral conveyor changes the elevation of the products.
2. The system introduces product dwell time (for proofing, curing, cooling, drying, etc.).
3. The OutRunner Spiral promotes product offloading (accumulation).

Changing elevation of a product is probably the top reason customers purchase the OutRunner Spiral and other spiral conveyors. These systems give you the ability to go from one elevation to another with a relatively small footprint and without the need for special automation. Spirals are unique for this as they are literally just conveyors formed into helical shapes. If your product can be transported at an incline on a standard conveyor, it can also be inclined with the OutRunner Spiral conveyor.

Some products require time to rest for various reasons — bread dough needs time to rise (proof), some glues or chemical reactions need time to cure and other products need time to cool off or dry after being baked, washed or cooked. Like the OutRunner Spiral system, a spiral elevator allows for a very large amount of product to be temporarily held while still being on the production line.

Because the OutRunner Spiral conveyor and other spiral systems can hold a large amount of product, they are sometimes used for product accumulation. However, most spirals are not good solutions for that because once a product enters a spiral, it must travel all the way to the exit before it can re-enter the production line. Almost all spirals are “FIFO” (First In, First Out) and are not designed to run in their opposite direction. There are specialty spiral applications designed for this sort of thing, but they are very large and extremely costly.

What are the Advantages of the OutRunner Spiral?

Compared to other changing elevation solutions at Span Tech, there are many advantages of the OutRunner Spiral worth exploring. However, the top two benefits are in the system’s overall flexibility and robustness.

OutRunner Spiral Flexibility

The OutRunner Spiral can be designed with an infinite amount of possibilities to meet the specific needs of your company’s assembly system:

Many chain widths available
A large range of minimum/maximum conveyor elevations
A large variety of chain styles (high friction, cleated chain, etc.)
Exit orientation options (4 exit orientation options for a 4-tier spiral, 6 for a 6-tier)
Custom conveyor centerline radius
Custom number of tiers
Clockwise/counterclockwise direction
Material of construction (powder coated or stainless steel)
Up/down flow
Extended infeed/outfeed conveyor lengths

OutRunner Spiral Robustness

Like all Span Tech products, our OutRunner Spiral is designed to last. To help prevent any over-torque situation, we ship every spiral with a torque-limiter designed into the drive train. If the torque ever exceeds a certain amount (something becomes jammed), the torque limiter will “trip” allowing the system to safely stop.

Optimize Your Facility With the OutRunner Spiral Conveyor

Since its introduction in 2006, the OutRunner Spiral conveyor continues to revolutionize the workflow of warehouses and facilities across the U.S. If your productivity could use an enhancement, don’t wait any longer. Start a free estimate today, and one of our pros will get back to you within one business day. And, if you have any questions about the OutRunner Spiral, contact us at any time, and we’ll be more than happy to help.

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A Quality Warehouse Starts with People

Posted on April 6, 2021January 10, 2023 by Span Tech

A quality warehouse — every manufacturer craves it. That’s the ability to ship products to end-users on time and with the correct, undamaged materials inside. Every distribution center favors it, too. It’s what a good company does. Suppose it were only that simple. Often, warehouse quality control is deficient or even nonexistent. There are no quality control methods in place and no employees — or the wrong employees inspecting the overall process. Is it the fault of management? The employees? The QA leader or team? The answer is often complex but easily solved by a culture shift like the one undertaken at Span Tech.

It’s about people. The answer to having a quality warehouse is to start with good people taking ownership of their work. Empower them to have the freedom to pull something back or inspect a product again to be sure it’s right before going forward to the next person. Then they take responsibility. And this keeps going until a quality control process drives the great product you make right into the end user’s hands with no mistakes. This article examines the crucial piece in the quality control puzzle and develops a warehouse quality control plan where everyone’s involved.

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Why Is Quality Control Important?

Remember, the key is people. We can put perfect processes in place, but the people either make it or break it. Warehouse quality control does have steps to help guide you through the processes, but empowering the people at each stage is the key to optimal performance.

You can’t assume that the departments handling the product before you followed the same quality control procedures. Still, the buck will stop with you — the first person in the chain of command who follows QA procedures and takes responsibility for what you can control. Without empowering every employee in the chain to take charge of their jobs, you’ve already located your weak link(s).

Here’s a quality control process that can work as a checklist for a production warehouse inspection:

Safety Check: This should be your first and last item in warehouse quality control. Make sure the conveyor belts — or whichever part of the production chain you’re linked to — are operating correctly and that no safety hazard poses a threat to employees. Every warehouse quality control plan must include detailed safety procedures.
Inspect Materials When Received: Whether you’re in Receiving and inspecting the raw materials and products your company uses; in Shipping where a conveyor belt feeds boxes being sent out; or working on the production line itself, inspect, inspect, inspect.
Prior to Full-Production Inspections: Pull one finished product and inspect. If it passes muster, proceed with the run.
Inspection During Normal Production: At intervals, pull a partially finished product and inspect.
After Production Inspections: A predetermined quantity of product will be pulled and inspected.
QA Leader Inspection: The person with final authority will inspect the product before shipping. This quality control process is an ongoing and ever-evolving activity. You must evolve, too, to meet new, more significant inspection challenges.
Safety Check:One last item of great importance, especially if another shift will come online — the safety inspection! Ensure any hazards are removed and the all-clear is given.

While this list follows a production line, the shipping department’s efforts are also critical, as they are the last line of defense against error. And if you are a distribution center only, the conveyors full of boxes and packages act as your production line.

What Does Quality Control Mean?

While there are many correct answers to this question, the focus should always be on the people more than the process. Taking time to ask yourself, “What does quality control mean?” is a great exercise to revisit often. Of course, as a business, you need steps to follow and regular assessments of your product’s quality to remain successful. But quality control is more than a list of rigid rules. It should be more than just a list of quality control methods that work. Overall, quality control means:

Every employee understands their roles and job requirements and can fulfill them with competence.
Every employee is empowered to make decisions that can affect production or distribution to make sure the product — at their point in the production process — is correct.
Every employee takes responsibility that every product at their station is accurate, and if not, calls attention to it or fixes it themselves.
Everyone — including upper management — cares about 100% correct products leaving their company every time.

It’s this type of commitment that ensures a quality warehouse and a 100% correct product reaching the end-user.

How to Create a Quality Control Process

Now that you have your employees empowered to bring the kind of change you want, it’s time to create a quality control process. Span Tech has developed a safety-first working environment based around people. People are our heart and soul. They’re the reason our quality control is a seamless process, resulting in the highest quality products for our customers. Span Tech’s Quality Promise follows these seven principles:

1. Personnel: Be sure to hire and retain top-quality employees, then put the right people in the right places. When well-placed employees are empowered, you’ll see them take ownership of their link in the production chain. And that’ll make all the difference in warehouse quality control.
2. Relationships: Value the relationships you develop with your suppliers. Still, make sure they meet your rigorous standards regarding the products and raw materials you purchase. If there’s a problem, offer practical solutions to resolve it quickly.
3. Technology: Span Tech is a leading innovator of conveyor solutions because of the people we count on every day using the first-class equipment and warehouse quality control procedures already in place. Be sure to give your employees state-of-the-art technology and equipment, so they can produce top-shelf products.
4. Documentation: Take the time to record and ensure your quality control procedures are clearly defined for each stage of your production. Whether in-house job instructions or engineering and design projects, produce accurate, understandable, and consistent documentation across all departments. If even one employee can’t clearly understand the instructions they’re to follow, work with that person to determine if the documentation needs reworking. Always retain good people — documentation is easier to replace.
5. Verification: Stay committed to making sure your products work as intended and are correct to the finest detail. Use appropriate measuring tools when testing to be confident each product is as it should be. If a product doesn’t meet high standards, your customers should never be the ones to tell you.
6. Dedication: Quality control methods would be meaningless without committed and empowered employees. The power behind Span Tech is our people. Like us, you’ll need competent, empowered employees who do things the right way every time. Their dedication makes it possible for you to offer the highest quality products and services to your customers.
7. Practice Prevention: Catching and solving problems before they leave your facility is critical to success. Taking appropriate actions to avoid defects starts with clearly understanding your customers’ requirements. What they expect should be your standard and the baseline of your production. Go above and beyond their requirements with unwavering quality and reap the benefits of success.

Safety is a Quality Control Process

A safe working environment is critical to any quality control process. As you put these inspection techniques in place, remember that safety must come first! We designed our conveyor systems with that in mind. Our EZGUIDE™ Conveyor Guide Rails replaces the brackets or rods that most conveyor belts have. These brackets and rods often stick out from the sides when the belt is in the “retracted” position. That poses a safety hazard in any warehouse or distribution center. With this type of safety hazard, warehouse quality control is already lost due to the dangers posed to employees by their conveyor belts.

EZGUIDE™ has no mechanical components protruding from the sides during adjustment. And EZGUIDE™ GUIDE RAILS remain adjustable through conveyor belt curves. If you believe people are your company’s heart and soul, any quality control process must start with ensuring their safety. That commitment has helped Span Tech become an industry leader as an innovative manufacturer of conveyor belts.

Span Tech and Warehouse Quality Control

Developing a warehouse quality control program is much easier when recognizing your employees are your number one asset. Instead of identifying “things” to change or rearrange, identify people. Placing the right person in the right job will help prevent defects before your checklist even begins. Put the best people in the safest environment and give them clearly defined roles and responsibilities while empowering them to make decisions. Quality control procedures will flow organically as you make a step-by-step map of your entire production or distribution procedures. Finally, hiring or identifying the right employee for the job of making the final inspection is highly important. They’re the last person to see the product before it ships out to the end-user.

Choose Span Tech for Warehouse Quality Control Solutions

Span Tech believes in people. Our people make the highest-quality conveyor belts on the market. That’s because each one knows they’re essential to the entire quality control process exactly where they are. And so on down the line. If you’re still using a bracket and rod conveyor belt system, consider the safe, reliable and innovative EZGUIDE™ Adjustable Guide Rail. It may be the best first step on your way toward warehouse quality control. Contact us, and we’ll provide the best solutions for you today!

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The Advantages to the OutRunner Spiral Conveyor System

Posted on March 29, 2021March 29, 2021 by Span Tech

What Are Spiral Conveyors?

Spiral conveyors pack a long distance into a small footprint. These types of changing elevation conveyors have been used for many decades to cool bakery products as they exit the baking process, as well as other food production applications. The old way of driving these conveyors uses a large, powered drum in the center. The conveyor chain is wrapped around the drum and, through friction between the chain and the drum, the chain is pushed forward. While there is an end drive separate from the drum drive that provides pull tension to the chain, the chain can still slip as the drum rotates.

In a typical drum spiral design, the chain runs against vertical cage bars that are spaced evenly to form a cylindrical shape. These bars have a slip-on plastic cover that protects the system from wear. Unfortunately, the major weakness of all drum-driven spirals is sanitation. Since the conveyor runs on a support system that is fabricated around the drum, the chain must be removed to clean the drum’s cage bars. In fact, some spiral conveyors have thousands of feet of chain, which makes the cleaning process a very long and impractical process. That’s why sanitation engineers typically look in the spirals first during an outbreak of bacteria.

In the case of the technology present in the OutRunner Spiral conveyor, however, this new system changes how these spirals are driven. Let’s look further into this solution and break down the benefits of the OutRunner Spiral machinery.

About the OutRunner Spiral Conveyor System

The OutRunner Spiral conveyor system was developed to eliminate the drum drive system altogether. Instead of wrapping the chain around a moving cylinder, this design drives the chain along its outside edge by an external sprocket. OutRunner Spirals use a vertical drive shaft with a sprocket on each tier, and the drum is eliminated in this design. Depending on the diameter and width of the chain, there can be more than one drive shaft with sprockets. These shafts are all tied together on a common mechanical connection with no electronic synchronization used, making this one of the biggest advantages to the OutRunner Spiral.

The second weakness of classical drum drives is getting products off the conveyor chain itself. Drum drive systems use long pitch chains which are usually 2” (50mm). Any product that has an unused 4” in length can have difficulty transferring product off the end of the system. Additionally, transferring smaller items can become even more challenging. One of the benefits of the OutRunner Spiral, though, is that it combats this issue by using a “Pillow Top” chain. This chain has a rounded top which forms a perfect cylindrical shape at the end drive. A knife edge plate is fitted close to the chain, making product transfer successful, even for small items.

What Are Some Other Benefits of the OutRunner Spiral?

One of the biggest advantages to the OutRunner Spiral machine is the very low horsepower required to power the system. Because there are no frictional losses between the chain and a drum, the overall power required to drive the chain is much lower. Also, because there is no massive central drum to turn, the power required to get the system started and stopped is greatly reduced. Here is an example of just what this means:

The MOAS Spiral in Canada: This project has 1000 feet of 36” chain in 2 spirals, one going up and the other going down. These units use a single unbroken chain so there are no transfers between the units. This system is driven with a single ¼ horsepower drive. All the drive shafts are mechanically connected.

Add the OutRunner Spiral Conveyor System to Your Operations

When it comes to your daily business operations, you may be able to streamline your productivity with help from the OutRunner Spiral conveyor machine. However, Span Tech offers many options to optimize your workflow with dozens of specialty conveyor solutions. Whether you work in beverage production, e-commerce or packaging, our conveyors are highly efficient to handle your production demands for years to come. If you’re ready to reap the benefits of the OutRunner Spiral, or are interested in one of our other specialty conveyor systems, check out our equipment and contact us today with any questions you may have. We look forward to working with you!

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Tips for Keeping Up with Warehouse Demand in 2021

Posted on March 29, 2021September 22, 2023 by Span Tech

Time is money, and there is nothing more important than maximizing your warehouse’s ability to get high demand products off the floor, out the door and right to your customers. The ideal warehouse demand and supply is a balance that every company strives to achieve, but no warehouse and industry are the same. Finding a tailored solution to your specific warehouse demand requires the assistance of a company with the ability to tailor its products and services to your needs. Whether you are in need of a new conveyor or conveyance component and design solutions for optimizing an existing system, Span Tech’s custom designs, patented technology and expert knowledge are exactly what you require for keeping up with demand. The beginning of each new year is a chance to reevaluate customer demand and search for innovative solutions that can impact your bottom line, and 2021 is no exception. Let’s go over some conveyance tips and tricks that will help you deal with the high demand and new challenges that this year presents.

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Principles for Tackling Customer Demand with Conveyance

Your situation is unique, especially as it relates to your high demand products. Business models, warehouse facilities, industry demands, existing technology, and many other factors make your circumstances one of a kind. Before discussing specific solutions for optimizing standard and specialty conveyor systems, here are some basic principles that hopefully apply to your situation regardless of your individual circumstances:

Stick With What You Know

Since goods-to-person order fulfillment runs on automation, it allows your warehouse to run at a greater level of efficiency. Through the use of state-of-the-art technology, your staff will have the ability to meet peak demands and fulfill orders seamlessly.

Scalable Resources & Technology

Supply and demand will fluctuate for any given industry. When you experience rapid changes in customer demand, scalable resources and technology can be extremely helpful in keeping up with demand that is either increasing or decreasing. Whether it is working with temp agencies or third-party logistics, the ability to scale your resources and technology to your needs.

Prepare for High Demand When Business Slows Down

In addition to scalable resources and technology, which allows your warehouse to quickly respond to changes in demand and supply, it is important to prepare for times of increased demand. You never want to find yourself in a position where there are not enough goods to sell to your customers. If you are able to identify when your business commonly experiences times of high demand, such as seasons and holidays, you can anticipate the fluctuations of demand and supply to start preparing during slow periods.

Avoid Warehouse Overload

While a warehouse with not enough goods to sell is a bad position to be in during times of increased demand, you also do not want to overload your warehouse. You have a variety of options to avoid warehouse overload and balance changing supply and demand:

Reduce inventory or upgrade technology
Add warehouses or limit the territory you serve
Optimize storage methods for time and space
Increase operation hours or outsource

Look to Invest in Superior Conveyance Technology

Upgrading your existing standard conveyor system with the latest and greatest innovations can help you maximize your efficiency and uptime to compensate for high warehouse demand. Our experts are constantly working to improve even the current conveyor solutions in anticipation of the new and growing conveyance demands in a variety of industries. If you are looking for a superior conveyor system to overcome growing customer demand, Span Tech can help you find a custom convey solution for you and your industry.

Find a Custom Conveyance Solution for High Demand Products & Industries

Beyond adhering to the general principles for tackling warehouse demand above, optimizing or restructuring your current mode of operations will often demand a customized solution for your specific business, infrastructure and industry. Span Tech and our in-house team of experts can work with you to craft a unique conveyor system. We can help you:

Innovation for Keeping Up with Demand

If you have a material handling problem that no one has been able to solve, let us try our hand at it. We thrive on the opportunity for new innovations! Our engineers enjoy a challenge and constantly create conveyance inventions and component solutions that can help your specific situation and other businesses facing similar issues.

Conveyor Testing to Supply High Demand Products Long-Term

We design, invent, manufacture, install and maintain our conveyor systems. It only makes sense that we also thoroughly test our conveyor systems, especially when it comes to your specific high demand products. We can test all of our conveyor solutions, including:

Addressing Customer Demand in Your Industry

Our customizable technical solutions for processing applications can be adapted to your industry-specific needs in high demand markets. Span Tech has vast amounts of experience creating tailored conveyor systems for food production, packaging, pharmaceuticals, e-commerce, cosmetics and much more. We will work with you to develop an industry-specific solution for warehouse demand.

Get Custom Conveyor Systems for High Demand Industries

Whatever your application or industry needs, the experts at Span Tech can develop a custom directional conveyor solution to address your unique customer and warehouse demands. Whether you’re interested in our standard conveyors or specialty conveyors, our team can help you find an optimal solution for your business among our premium conveyor products. Contact us to learn more about keeping up with demand using our conveyor solutions or speak to our troubleshooting experts for help with an existing system. See what Span Tech can do to help you keep up with industry and customer demand!

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