Conveyors and Material Handling

Targeting manufacturers and consulting contractors, these comprehensive planning, design, and manufacturing data generation solutions are supported by years of experience, knowledge, technology, and continuous improvement.

Projects

100+

Hours Worked

8000+

Clients Served

5+

Overview

The conveyor business is a challenging and dynamic industry that needs accuracy, effectiveness, and creativity in its solutions. In order to satisfy these needs, we have a complete solution, which is specific to the conveyor manufacturers and also to the contracting companies, which are engaged in the consulting and implementation. We offer end-to-end services to large commissioning projects where we do all the work, such as the initial estimation and planning of the cost, design, and implementation. We have a wide experience on conveyors across different industries, e.g., logistics and warehousing, food processing, packaging and bottling, earth moving and outdoor processing, among others.

Our solution starts with the fast and accurate creation of plans and drawings with the help of the latest roller conveyor CAD programs, which helps in the accurate sales quotation and efficient project pricing. We maintain effective communication with the stakeholders to make them agree on the project goals and requirements. After the confirmation of a project, we work on detailed design, generate 3D models, simulations, manufacturing drawings, CNC data, Bills of Materials, and O&M manuals. Due to our profound understanding of the industry, we are able to perfect and shape designs to suit the changing material handling industry. Our speed, accuracy, and expertise ensure that we offer high-quality solutions that are reliable and meet the expectations of the industry.

Our Expertise

Planning Engineering

Designing a big project of conveyors implies organizing the complex requests and providing careful implementation. This is made easy through our solutions, where we offer comprehensive support to the end. We begin with the use of the most current CAD tools that help to quickly develop detailed plans and drawings, which are the basis of proper estimation of costs and effective planning of projects. This is because with this kind of rapid production of the design documents, accurate and competitive sales quotations are possible, and the project prices provide a clear picture of the real cost and possible cost savings.

Autodesk Factory Suite and Navisworks are special CAD tools that minimize the chances of errors and omissions. We lay stress on ensuring there is clear and consistent communication between us and all stakeholders to enable the alignment of goals and specifications of the project, and understanding the same. Such a participatory style aids in uncovering and fixing the possible problems at an early stage to maximize the planning process and precondition a successful project execution.

Design Engineering

We go to the extreme of design, whereby with the use of advanced CAD tools, we create accurate 3D representations that describe all facets of the conveyor system. These models are essential in visualizing design, assessing the relationship in space, and identifying possible problems prior to fabrication.

We also perform thorough simulations to determine the performance under different working conditions, whereby the design is checked to be in line with the functional needs and the performance requirements. The manufacturing drawings are highly detailed to give very specific instructions that can be followed through to production, and the CNC data keeps the components machined with precision.

We also prepare extensive Bills of Materials (BOMs) to list all the parts and enable us to make precise purchases and manage the costs. Operation and Maintenance (O&M) manuals are also availed to facilitate users in the correct functionality, maintenance, as well as troubleshooting of the system.

Our Solution

The Conveyors and material handling Sales CAD solution will ensure prompt and effective replies to queries, but not only that, it will facilitate and speed up the design process. We use a simple design method, which makes use of more sophisticated software like Autodesk Factory Suite, AutoCAD Sketch Blocks, and Navisworks. These tools will allow us to create high-level 3D models relatively fast and with a clear and detailed visualization of the conveyor systems.

We make use of parametric single-part models to design conveyors in a spatial environment, that is, each element is modeled with exact dimensions and fitting. We have also devised ways of smoothly translating the CAD input of factory planning so that information generated on common software is compatible with our CAD software. This will improve data consistency and facilitate the planning process to allow easy and effective project implementation.

Our conveyor cost estimation is a solution that offers a holistic method of project expense determination. We consider not only the cost of the basic material and labor but also the requirements, like the complexity of the design, the requirements of the component, and the cost of manufacturing. We have included in our solution an assessment of the customization needs, quality, and type of components, and fabrication costs. We also consider costs incurred in installation and commissioning, such as preparation of the site, skilled labor, and testing of the systems as well.

Our estimates will include shipping and handling costs, and also the maintenance and support costs, such as service contracts and spare parts. We also guarantee adherence to the standards of regulations and any required certifications and precautions. Also, our solution will accommodate overheads, markups, and possible contingencies to meet unexpected costs. Taxes and duties on importation are also taken into account. Through these considerations, we give you the right cost estimates that are comprehensive and which are certain to be clear and precise when it comes to your conveyor projects.

We have a variety of conveyors that are designed in detail, such as belt, lineshaft, slat chain, modular belt, gravity, zero-pressure accumulation, chain, and pallet conveyors, among others. We are conversant with the conveyor health and safety requirements in different industries, including warehousing, medical, material handling, food processing, and packaging. We have specialized in designing auxiliary equipment such as transfers, lane changers, access gates, overhead walkways, box pushers, and merges.

Our data is of frequent production techniques such as sheet metal fabrication, structural steel welding, and machining. The drafting and drawings are based on the international standards, which makes it precise and consistent. CAD designs are focused on re-usability and well well-structured modeling strategy, which gives efficient changes and scaling. We create customized conveyor designs that are innovative and reliable to meet the specific needs of the customers, using our vast experience and knowledge to create unique designs that are specific to each customer.

The conveyor and material handling is our CAM (Computer-Aided Manufacturing), which provides end-to-end solutions to a production process, making it more precise and efficient. Our CAM services entail the transformation of elaborate CAD models into accurate manufacturing guidelines that are subsequently employed to regulate machines and manufacture parts with high accuracy. This involves the generation of tool paths, optimization of machine work, and the production of G-code for the CNC machine.

For a variety of components that are necessary for conveyor systems, such as belt sections, frames, rollers, sprockets, brackets, and custom parts, we specialise in CAM. Through accurate cutting paths, effective nesting strategies, and minimising excess material usage, our cutting-edge techniques aim to reduce material waste. We use cutting-edge equipment and software to maximise production, guaranteeing that every component is made to precise specifications while reducing waste and expenses.

Our CAM solution offers substantial advantages to our clients. Reducing material waste helps to promote sustainable manufacturing practices while also lowering production costs. Our accurate and efficient manufacturing procedures produce parts of superior quality, which lowers the need for rework and boosts the conveyor system design overall dependability. Furthermore, our capacity to manage intricate and customised part designs guarantees that we can satisfy each client’s particular requirements by offering specialised solutions that improve the effectiveness and efficiency of their material handling operations.

Our documentation solution ensures clarity, compliance, and efficient communication while offering complete support for all facets of material handling and conveyor projects. We produce a range of documents to suit diverse requirements:

Compliance Documents: These documents guarantee that all systems follow the rules and guidelines set forth by the industry. They provide information on how the equipment satisfies legal and safety requirements and include safety certifications, regulatory compliance reports, and inspection checklists.
Installation and Commissioning Guides: These manuals offer detailed instructions for assembling and powering up the conveyor systems. They guarantee a seamless and effective installation process by covering site preparation, assembly techniques, initial calibration, and system testing.
Operation and Maintenance (O&M) Manuals: O&M manuals provide comprehensive guidance on how to operate the machinery, perform regular maintenance, troubleshoot issues, and take safety precautions. They are necessary to ensure safe operation and extend the conveyor systems’ lifespan.

Using templates and CAD software to streamline the documentation process ensures consistency, accuracy, and efficiency. By utilising these tools, we can quickly generate detailed and professional documents, tailored to the specific needs of each project, offering valuable support from installation through to maintenance and marketing. On the marketing side, we create high-quality brochures and photorealistic renders that showcase the design and functionality of our conveyor solutions. These materials are crucial for communicating the value and benefits to potential customers.

For effective design, revision control, and data organisation, our conveyor CAD database management service is essential. It entails the methodical management, upkeep, and storage of all roller conveyor CAD model and related design documents. To keep reliable and secure data repositories, we use Product Data Management (PDM) and Product Lifecycle Management (PLM) software.

Our PDM and PLM platforms use version control systems to carefully manage design revisions. This makes sure that all changes are recorded and that historical data is kept safe, making audits and rollbacks simple. To ensure accuracy and consistency, design modifications are methodically recorded, examined, and approved.

Our CAD models can be effectively used for subsequent projects because they are made with reusability in mind. We keep distinct databases for reusable designs and individual projects, making it easier to find and retrieve pertinent models quickly. Design time for new projects is decreased, and productivity is increased with this dual-database approach.

We use SKU (Stock Keeping Unit) systems to further organise our data. Every model and component has its own SKU, which makes it easier to quickly identify and classify particular parts. Our design process is streamlined, effective, and able to handle the intricate requirements of the material handling sector thanks to this methodical approach to database administration.

Our Work

Tabbed Interface

Packhouse System

This is a high-capacity packhouse conveyor that is able to effectively manage both empty cartons and packed fruit. It encompasses numerous types of conveyor, e.g., belt conveyors, powered bends, gravity rollers and skate wheels, roller chain conveyors, automatic box pushers and diverters, as well as lineshaft conveyors.

The empty cartons are emptied on the ground floor on a three-tier conveyor that slopes off before entering the packing room. In this case, they are divided automatically into six lanes and supply six conveyor lines. The fruit is transferred to the packing room through roller chain conveyors out of the fruit bath, with excess water dripping off before being transferred to the packing room. Lineshaft conveyors are used to pack fruit afterward to give accumulation. Waste is also removed from the packing room by a belt conveyor into the waste management system.

The system will be an integrated conveyor system that offers continuous and efficient flow of materials, hence maximizing the packing process and also managing the waste.

Curing System

This project was not restricted to handling materials but also to the design of an automatic high-temperature oven to cure large cement boards. The boards are conveyed into a slow-moving, multi-level conveyor, which heats the boards and then inspects and physically tests them using automated OEM equipment.

The conveyor line feeds the board onto a chain conveyor system, which is then transferred to a lift which is specially designed lift. This lift takes the board to one of the seven levels of a low-speed chain conveyor, with the remainder of the levels being able to be supplied by the fast infeed without slowing down the process. On exiting the oven after curing, the board is taken out of the oven through a similar mechanism on the other side and then loaded to be examined and tested, and then palletized.

The whole system, including the outer structure, was in-house designed, showing a holistic approach to incorporating the advanced automation and processing the handling processes with better efficiency and quality control.

Curing Conveyor

This was a project that was conducted in cooperation with a robotics production firm to develop an effective production line to be used in manual assembly processes of electronic items. The system will be designed in such a way that it moves to different workstations, with customized palletised electronic parts to be handled manually in order to provide a smooth workflow. Moreover, it has a scissors lift and overhead conveyor that transfers finished parts to the base station, which improves productivity and ergonomics.

The consideration of safety and visibility is the priority; therefore, the primary conveyor line is covered with acrylics, which allows controlling the processes inside the company without any threats. The system combines numerous conveyors such as belt conveyors, driven roller conveyors, zero-pressure accumulation zones, and belt transfers. Every type of conveyor is chosen according to its purpose in keeping the elements of the assembly process flowing smoothly and in a controlled manner.

The innovative design of this versatile setup ensures a high level of safety and operational control coupled with high efficiency, which is why it can be considered an optimal solution to assemble electronic products.

Carousel Conveyor

The design in this project is a special one, and it has been traditionally controlled using modular belt or slat chain conveyors, which are usually of high radius. Rather, we came up with a new carousel system consisting of inclined belts and rail fix transfers to move products around in an efficient manner.

This type of approach is the one that is able to offer a smaller layout and provide more control over product movement to meet the specific needs of the application. It is also a design that gets rid of dead space that is usually generated when products flow between the head and the tail section that are in contact with each other.

With the use of inclined belts and rails attached to the wall, we managed to provide a continuous movement in the small area, which increased the functionality and efficiency of the system.

Sanitizing Tunnel

COVID-19 compelled industries to change their functioning greatly, and the consumer goods segment was not an exception. Most of the requests during this difficult period were designed towards the introduction of sanitizing systems into the available setups.

To this, a sanitizing tunnel was produced to be fitted in with the conveyor systems that were already in use, and where the products traversing the conveyor assortment are disinfected. This tunnel has sanitizing nozzles that are well-positioned to sanitize products effectively, giving a required layer of security and hygiene.

Produce Processing

It is a small-scale produce processing system that is meant to do comprehensive cleaning, sorting, and binning of fruits and vegetables. It has a high platform that is space-efficient. It begins with an elevating roller chain conveyor in a bath, which picks up produce in a bath and passes it through automatic washers with brush rollers to extract all the dirt. Produce is hand-sorted and inspected after the initial washing. Poor quality products are thrown through a tube into a waste belt, which moves them to a waste bin.

The produce is then subjected to secondary cleaning cycles and then on to an automatic sizer, where the produce is assessed and transported to the belt conveyors that will fill different containers with produce, such as boxes and bins. There is a secondary manual sorting line equipped with chutes that can be used in case of hand sorting.

This system is used to guarantee total cleaning, proper sorting, and binning, with high-quality standards.

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