A Monthly Newsletter 

from Babush Material Handling Systems, Inc.  
  August 2004  
Your Single Source Solution

Wrapping up at ProMat 2005

January 2005-Chicago, IL

Over 800 material handling and logistics providers showcased their productivity solutions for warehousing, manufacturing, logistics and distribution operations at Promat. This year the show had a primary focus on the various mandates for RFID implementation imposed by Wal-mart, DOD and others for 2005. Overall, the show’s attendance was brisk and the initial feedback was very positive, making it a successful show and pointed to the fact that 2005 is the year that many companies will be dealing with RFID implementation.

Attendees came seeking new solutions for the best way to handle RFID implementation and to reduce costs and increase productivity using the most efficient material handling systems in their operations. The Star Alliance Center was glad to offer assistance in providing ideas on the best way to implement RFID and to reduce the costs of your material handling and logistics operations.

The Star Alliance Center showcases an RFID test loop which demonstrates material handling equipment and systems that significantly increase productivity and profitability. The center is open to anyone interested in learning more about RFID challenges and opportunities. Whether you are interested in touring the facility for the first time or would like to test your product in a real-world RFID environment, the Star Alliance Center is a key resource for evaluating RFID solutions. Let the Star Alliance Center start working for you! Contact us for more information or visit our website www.babush.com.

LIVE! RFID Test Loop Demonstration

If you are considering RFID implementation or the need to reduce costs and improve efficiency in your material handling operations then join us on February 15, 2005 to see a live RFID test loop. We will have experts on both RFID implementation and material handling systems available to answers any of your questions and discuss how you can dramatically improve your company’s bottom line!

Register to attend our Live RFID Test Loop Demonstration
February 15, 2005 from 9:00 AM until noon





Quick Tip of the Month

Manual Palletizing

Manual palletizing is usually done at a very low elevation, where pallets are picked up by a lift truck or pallet jack from the floor or low level conveyor. Operators are typically reaching to the far side of the pallet while bending over, or walking around the pallet to hand load individual cartons, etc. This leads to back stress/injury, fatigue and a lot of wasted motion and time.

It is estimated that approximately 40% of the time put into hand palleting is spent manuvering around the pallet!

A Pallet Pal, by Southworth, is a simple pallet leveling device that brings the pallet to a higher elevation to eliminate bending down by the operator. This devices may be accuated by springs, pneumatics or hytraulics and, all are available with turntable options. This is a very inexpensive solution for wasted time, injuries and workman's comp.

Case Studies

Visit our website (www.babush.com) for material handling case studies in a variety of industries.

This month we are highlighting the following case study:

Paper Manufacturer
(company name withheld)

System Integrator:

Babush Material Handling Systems, Inc.
Sussex, Wisconsin

The challenge was to improve quality and increase productivity through technology.

The justification for the new packaging system was to reduce damage to the finished product of paper sheets as it traveled from the warehouse to the printers. This required a packaging system that would seal the pallets of paper sheets and eliminate the harmful environmental conditions by restricting moisture and UV sunlight.

The secondary objective was to utilize state of the art equipment to replace the manual wrapping operations they were currently using. With this automated system our customer was able to reduce their labor force by 12 employees and provide their customer with an improved product.

Babush Material Handling went about the task of integrating the special equipment required for the packaging system and customizing the controls to monitor the process from start to finish.
One of the critical factors became the necessity to convey the unwrapped pallets of paper sheets with a maximum weight of 4000 lbs. between each stage of the packaging system. For this reason chain-driven-live-roller conveyor was chosen to ensure reliability with no disruption of the paper sheets during transportation from station to station. By incorporating soft start/stop controls on the conveyors we were able to guarantee the paper remained stable throughout the various equipment stations.

At the beginning of the conveyor line the pallet is stopped at the weigh station. The height, width, length, and weight of the pallet is measured. This information is transmitted to the customer’s host computer for verification. If the pallet information doesn’t match the pallet’s bar code, the pallet is rejected and sent back to the loading station. If the pallet is good, the pallet advances to the centering station where the sheets of paper are guided and repositioned to ensure they are located squarely on the pallet. The pallet then proceeds to the top-film station. Here a layer of shrink film is laid on the top of the pallet with some overhang on all four sides. Because the control system tracks the pallet size throughout the process, the system is able to run various pallet sizes automatically without assistance from the operator. Then it’s on to the film wrapping station where the pallet advances through a film curtain. Once the pallet is through the film curtain, the trailing edge of the curtain is sealed with a welding beam to recreate the curtain.

At this point, the pallet reaches the most important station. This is where the pallet enters the film-shrinking oven; the top film and side film sheets are heated by blowing hot air from 4 sides and the top. This results in a very tight and uniformly wrapped pallet when the sheets of film fuse together to form a single wrap. After the pallet is removed from the oven it stops at the cooling press station where pressure is applied to the top of the load as it cools to ensure the most compressed and strongest package possible. The pallets are off to the operator station where they apply a label that is generated by the host computer. The pallet will then travel either directly to the loading dock or to an AGV loading station. The AGV will then transport the pallet to the customer’s high-rise storage system.

This system utilizes specialized equipment manufactured in Germany. This presented a unique challenge, first dealing with the translation of technical data from the German language to English. Secondly the German equipment was designed for Siemens controls (the predominant architecture in Europe). Our customer preferred to use Allen Bradley architecture to insure commonality within their facility and allowing them the ability to receive service locally. Through a strong commitment to detail and dogged determination, the system was designed and completed in the allotted timeframe. Our customer was able to put the new pallet wrapping system online and eliminate the need to manually wrap their products from that day forward.

Read more case studies at our website


About Us

Babush Material Handling Systems, Inc. provides state of the art material handling services through rapid development of new technologies and partnering programs. With over 75 years in material handling integration, Babush is positioned to provide you with the most cost effective solutions, on time deliveries, and high quality customer care for all of your material handling integration needs. Some of our services include: Audits & Consulting, Layout & Simulation, Project Management, Turnkey Installation, Maintenance & Services, and more. Visit our website for more information and to find out how Babush Material Handling Systems, Inc. can become your Single Source Solutions Provider!