Wrapping up at ProMat 2005
January 2005-Chicago, IL
material handling and logistics providers showcased their productivity
solutions for warehousing,
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.
Star Alliance Center showcases an RFID
test loop which demonstrates material handling equipment
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
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!
to attend our Live RFID Test Loop Demonstration
February 15, 2005 from 9:00 AM until noon
Quick Tip of the Month
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.
Visit our website (www.babush.com)
for material handling case studies in a variety of industries.
This month we are highlighting the following case
(company name withheld)
Babush Material Handling Systems, Inc.
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
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
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.
more case studies at our website
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!