Conveyors and Material Handling

Comprehensive planning design and manufacturing data generation solutions, backed by years of experience, knowledge, continuous improvement and technology, targeted towards manufacturers and consulting contractors

Projects

100+

Hours Worked

8000+

Clients Served

5+

Overview

The conveyors industry is dynamic and demanding, requiring precision, efficiency, and innovative solutions. To address these needs, we offer a comprehensive solution tailored for both conveyors manufacturers and contracting firms involved in consulting and execution. Leveraging our extensive experience and expertise, we provide end-to-end support for large commissioning jobs, covering everything from initial cost estimation and planning to detailed design and implementation. Our expertise in conveyors spans a diverse range of industries, including logistics and warehousing, food processing, packaging and bottling, earth moving, and outdoor processing, among others

Our approach begins with the rapid and accurate generation of plans and drawings using advanced CAD tools, which aids in precise sales quotations and effective project pricing. We ensure clear and consistent communication with stakeholders to align on project goals and requirements. Once a project is confirmed, we focus on detailed design, producing 3D models, simulations, manufacturing drawings, CNC data, Bills of Materials, and O&M manuals. Our deep industry knowledge enables us to refine and innovate designs, adapting to the evolving material handling sector. We combine speed, accuracy, and expertise to deliver high-quality, reliable solutions that surpass industry expectations.

Our Expertise

Planning a large conveyors project entails managing intricate requirements and ensuring meticulous execution. Our solutions simplify this process by providing thorough support from inception to completion. We start by utilizing advanced CAD tools to swiftly create detailed plans and drawings, which form the foundation for accurate cost estimation and efficient project planning. This rapid generation of design documents allows for precise and competitive sales quotations, ensuring that project pricing reflects true costs and potential savings.

Use specialized CAD tools such as Autodesk Factory suite and Navisworks reduces the risk of errors and omissions. We emphasize clear and consistent communication with all stakeholders to ensure that project goals and specifications are aligned and fully understood. This collaborative approach helps in identifying and resolving potential issues early, optimizing the planning phase and setting the stage for a successful project execution.

We dive into detailed design, utilizing advanced CAD tools to produce precise 3D models that capture every aspect of the conveyor system. These models are crucial for visualizing the design, assessing spatial relationships, and identifying potential issues before fabrication begins.

We also conduct comprehensive simulations to analyze performance under various operational scenarios, ensuring that the design meets all functional requirements and performance standards. Our manufacturing drawings are meticulously crafted to provide clear, actionable instructions for production, while our CNC data ensures that components are machined with exacting precision.

Additionally, we generate detailed Bills of Materials (BOMs) to itemize all components, facilitating accurate procurement and cost management. Operation and Maintenance (O&M) manuals are provided to guide users in the proper operation, maintenance, and troubleshooting of the system.

Our Solution

Our Sales CAD solution for conveyors and material handling is designed to streamline and accelerate the design process, ensuring quick and effective responses to inquiries. We employ a simplified design approach that leverages advanced tools such as Autodesk Factory Suite, AutoCAD Sketch Blocks, and Navisworks. These tools enable us to quickly generate high-level 3D models that provide a clear and comprehensive visualization of conveyor systems.

 

Our process involves creating plan drawings that are essential for stakeholders to make informed decisions, allowing for a detailed review of the proposed solutions. Modifications to CAD models are made simple and rapid, significantly reducing time spent on revisions and updates, and enhancing responsiveness to client inquiries.

 

We utilize parametric single-part models to accurately represent conveyors in a spatial context, ensuring that each component is depicted with precise dimensions and fit. Additionally, we have developed methods to seamlessly translate CAD input from factory planning, ensuring that data created in common software integrates smoothly with our CAD tools. This capability enhances data consistency and streamlines the planning process, facilitating efficient and effective project execution.

Our conveyor cost estimation solution provides a comprehensive approach to accurately determining project expenses. We factor in not only the basic material and labor costs but also essential elements such as design complexity, component specifications, and manufacturing costs. Our solution includes evaluating customization requirements, quality and type of components, and fabrication expenses. We also account for installation and commissioning costs, including site preparation, skilled labor, and system testing.

 

Shipping and handling costs are integrated into our estimates, along with maintenance and support provisions, including service contracts and spare parts. We ensure compliance with regulatory standards and include any necessary certifications and safety measures. Additionally, our solution incorporates overheads, markups, and potential contingencies to cover unforeseen expenses. Taxes and import duties are also considered. By addressing these factors, we provide accurate, all-encompassing cost estimates that ensure clarity and precision for your conveyor projects.

Our detailed design solutions cover a wide range of conveyors, including belt, lineshaft, slat chain, modular belt, gravity, zero pressure accumulation, chain and pallet conveyors, and more. We are knowledgeable about conveyor health and safety standards across various industries such as warehousing, medical, material handling, food processing, and packaging. Our expertise extends to designing auxiliary components like transfers, lane changers, access gates, overhead walkways, box pushers, and merges.

 

We produce data for common manufacturing methods, including sheet metal fabrication, structural steel welding, and machining. Our drafting and drawings adhere to international standards, ensuring precision and consistency. Our CAD designs emphasize re-usability and a well-organized modeling approach, allowing for efficient modifications and scalability. With our extensive experience, we develop customized conveyor designs tailored to meet the unique needs of our customers, delivering solutions that are both innovative and reliable.

Our CAM (Computer-Aided Manufacturing) solution for conveyors and material handling offers comprehensive services that streamline the production process, ensuring precision and efficiency. Our CAM services involve converting detailed CAD models into precise manufacturing instructions, which are then used to control machinery and produce parts with high accuracy. This includes creating tool paths, optimizing machine operations, and generating G-code for CNC machines.

 

We specialize in CAM for a wide range of parts essential to conveyor systems, including belt sections, frames, rollers, sprockets, brackets, and custom components. Our advanced techniques focus on reducing material wastage through efficient nesting strategies, precise cutting paths, and minimizing excess material usage. We leverage state-of-the-art software and machinery to optimize production, ensuring that each part is manufactured to exact specifications while minimizing waste and costs.

 

The benefits of our CAM solution for our customers are significant. By reducing material wastage, we not only lower production costs but also contribute to sustainable manufacturing practices. Our precise and optimized manufacturing processes result in higher quality parts, reducing the need for rework and increasing the overall reliability of the conveyor systems. Additionally, our ability to handle complex and custom part designs ensures that we can meet the unique needs of each customer, providing tailored solutions that enhance the performance and efficiency of their material handling operations.

Our documentation solution provides comprehensive support for all aspects of conveyor and material handling projects, ensuring clarity, compliance, and effective communication. We create various types of documents tailored to meet different needs:

  • Compliance Documents: These documents ensure that all systems adhere to industry regulations and standards. They include safety certifications, regulatory compliance reports, and inspection checklists, detailing how the equipment meets legal and safety requirements.
  • Installation and Commissioning Guides: These guides provide step-by-step instructions for setting up and starting the conveyor systems. They cover site preparation, assembly procedures, initial calibration, and system testing, ensuring a smooth and efficient installation process.
  • Operation and Maintenance (O&M) Manuals: O&M manuals offer detailed instructions on operating the equipment, routine maintenance procedures, troubleshooting, and safety precautions. They are essential for prolonging the lifespan of the conveyor systems and ensuring safe operation.

On the marketing side, we produce high-quality brochures and photorealistic renders that showcase the design and functionality of our conveyor solutions. These materials are essential for communicating the value and benefits to potential customers.

We use templates and CAD software to streamline the documentation process, ensuring consistency, accuracy, and efficiency. By leveraging these tools, we can quickly generate detailed and professional documents, tailored to the specific needs of each project, providing valuable support from installation through to maintenance and marketing.

Our conveyor CAD database management service is integral to ensuring efficient design, revision control, and data organization. It involves the systematic storage, maintenance, and management of all CAD models and associated design documents. We utilize Product Data Management (PDM) and Product Lifecycle Management (PLM) software to maintain robust and secure data repositories.

 

Revisions in the design process are managed meticulously through version control systems within our PDM and PLM platforms. This ensures that every change is tracked, and historical data is preserved, allowing for easy rollbacks and audits. Design changes are documented, reviewed, and approved systematically to maintain accuracy and consistency.

 

Our CAD models are created with reusability in mind, allowing them to be efficiently applied to future projects. We maintain separate databases for individual projects and reusable designs, facilitating quick access and retrieval of relevant models. This dual-database approach enhances productivity and reduces design time for new projects.

 

To further organize our data, we implement SKU (Stock Keeping Unit) systems. Each model and component is assigned a unique SKU, helping in categorizing and locating specific parts swiftly. This structured approach to database management ensures that our design process is streamlined, efficient, and capable of meeting the complex demands of the material handling industry.

Our Work

Tabbed Interface

This large packhouse conveyor system is designed for efficient handling of empty cartons and packed fruit. It includes a variety of conveyors such as belt conveyors, powered bends, gravity rollers and skate wheels, roller chain conveyors, automatic box pushers and diverters, and lineshaft conveyors.

Empty cartons are fed at ground level onto a three-tiered conveyor that inclines before entering the packing room. Here, automatic diverters split them into six lanes, feeding six conveyor lines. Fruit is carried from the fruit bath into the packing room via roller chain conveyors, allowing excess water to drip off before entering the packing room. Packed fruit is then carried out using lineshaft conveyors, which provide accumulation. Additionally, a belt conveyor transports waste out of the packing room directly into the waste management system.

This integrated conveyor system ensures a continuous and efficient flow of materials, optimizing both the packing process and waste management.

This project extended beyond simple material handling to include the development of an automatic high-temperature oven for curing large cement boards. The boards are fed into a multi-tiered, slow-moving conveyor system where they are heat-cured and then undergo inspection and physical testing using automated OEM equipment.

The line shaft conveyor feeds the board onto a chain transfer system, which then moves it to a customized lift. This lift transfers the board to one of the seven levels of slow-moving chain conveyors, ensuring the fast infeed can supply different levels without delaying the process. After curing, the board exits the oven on the opposite side through a similar system and is then transported for inspection and testing before being palletized.

The entire system, including the outer structure, was designed in-house, demonstrating a comprehensive approach to integrating advanced automation and handling processes for improved efficiency and quality control.

This project was executed in collaboration with a robotics manufacturing company to design an efficient assembly line for manual assembly steps of electronic products. The system is engineered to transfer custom palletized electronic components to various workstations for manual operations, ensuring a streamlined workflow. Additionally, it features a scissors lift and overhead conveyor system that returns finished components to the base station, enhancing productivity and ergonomics.

Safety and visibility are paramount; thus, the main conveyor line is safeguarded with acrylic covers, allowing for safe monitoring of internal activities. The system integrates a variety of conveyors including belt conveyors, driven roller conveyors, zero pressure accumulation zones, and belt transfers. Each conveyor type is selected for its specific role in ensuring smooth and controlled movement of components through the assembly process.

This versatile setup not only increases efficiency but also ensures a high level of safety and operational control, making it an optimal solution for the assembly of electronic products.

This project showcases a unique design, traditionally managed with modular belt or slat chain conveyors, which typically have a large radius. Instead, we developed an innovative carousel system using inclined belts and fixed rail transfers to circulate products efficiently.

This approach allows for a more compact layout and precise control over product movement, addressing the specific needs of the application. This design also eliminates the dead space typically produced when products transfer from the head to the tail section, which are flush with each other

By integrating inclined belts and fixed rails, we achieved smooth, continuous circulation within the limited space, enhancing both the functionality and efficiency of the system.

COVID-19 forced industries to make significant changes to their operations, and the consumer goods sector was no exception. Many requests during this challenging time focused on incorporating sanitizing systems into existing setups.

In response, a sanitizing tunnel was developed to be integrated with existing conveyor systems, ensuring the disinfection of products moving along the lines. This tunnel features sanitizing nozzles strategically placed to effectively disinfect products, providing an essential layer of safety and hygiene.

This adaptation allowed companies to maintain their operations while ensuring the safety of their products and compliance with new health regulations.

This compact produce processing system is designed for thorough cleaning, sorting, and binning of fruits and vegetables. It features an elevated platform for space efficiency. The process starts with an elevating roller chain conveyor in a bath, lifting produce and transferring it to automatic washers with brush rollers for thorough cleaning. Post the first wash, produce is manually sorted and inspected. Substandard items are dropped via a chute onto a waste belt that carries them to a waste bin.

After inspection, produce undergoes secondary cleaning cycles before being sent to an automatic sizer for grading and outfed to belt conveyors, which fill various containers including boxes and bins. A secondary manual sorting line with chutes is available for hand sorting when needed.

This system ensures comprehensive cleaning, accurate sorting, and efficient binning, meeting high-quality standards.

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