Babush Increases Productivity 100%
Alta Resources, Inc.
Babush Material Handling Systems, Inc.
"Babush Material Handling Systems, Inc. was able to provide
Alta Resources with an automated conveyor system that
achieved the huge jump in productivity we were looking
for - throughput and productivity increased by 100%."
--Program Director Mike Ryder
The Desired Solution
New to the industry, Alta Resources started out with a
very manual system in order to get a handle on what type
of automation would give them the best results for the
future. Now ready for an increase in productivity, Alta
Resources called on Babush Material Handling Systems, Inc.
to design an automated solution while utilizing the same
amount of employees and warehouse space.
Upgrading and Improving
The manual system was first set up with the order pickers,
taking carts along two rows of flow racking selecting
items for each individual order. After the orders were
filled and the carts were full, they were wheeled down
to a table of packers that stuffed them into envelopes
for mailing. As a result of the location of the Gaylord
boxes, the packers were required to twist and turn to
place the envelopes in the Gaylord boxes to be sent to
the post office.
Babush designed a system that starts with a 65’ slider
bed belt conveyor. After filling individual orders, the
order pickers place them on the conveyor along with the
packing slip. The orders follow along the conveyor and
turn 90 degrees on a belted curve conveyor and then transfer
onto another 10’ slider bed belt conveyor, where
they are inspected by quality control. To eliminate possible
jamming and product damage, Babush modified and powered
the transfer rollers for a smooth transfer. This has proven
to be very valuable, as it allows the DVD and VHS movies
to move through the system with ease and keeps orders together
on the line. The orders continue onto a 30’ slider
bed belt conveyor with 10” wide model frames mounted
along the side creating a work table, with a 12” gap
between frames, for the packers to take the orders off
the belt conveyor and place into envelopes. The packers
then let the envelopes drop into the gap and onto chutes
attached to the bottoms of the work benches. This allows
the envelopes to fall onto a belted infeed conveyor running
along the floor that feeds a 14’10” incline
belt conveyor, which takes the envelopes and drops them
into a Gaylord box for shipment. Orders are filled by postal
zones that have been established by the postal service.
Upon completion of the orders for a specific zone; the
Gaylord is removed and replaced with an empty Gaylord for
the next batch of orders.
Controls used in this process were individual starters
with pushbutton start/stop stations on each conveyor. There
is a variable speed controller on the packing conveyor
to increase or decrease the speed, depending on how many
packers are present. In addition, there are E-stop pull
cords that run the full length of the conveyor system on
Benefits When Alta Resources, Inc. started
this project the movie club had 79,000 members and they
were filling 2,500 orders a day. They now have over 500,000
members and do 14,000 orders per day in the same facility.
- Facility Size: 35,000 sq. ft.
- Employees: 75 full and part-time
- Product Handled: DVD and VHS movies
- Types of Conveyors: Straight Slider Bed Belt Conveyor,
Curved Slider Bed Belt Conveyor, Incline Belt Conveyor
View case study online at our website
Quick Tip of the Month
How to Adjust Conveyor Drive Chain Alignment and Tension
Your conveyor's drive chain and sprockets should be checked
on a regular basis to insure proper tension, alignment
and lubrication. Improper adjustment or lubrication may
cause noise and/or extensive wear to the drive components,
resulting in a shorter life cycle and decreased conveyor
performance. The good news is that it’s something
you can easily adjust and maintain. See illustrations (figures
21A-21C) below to help you with this information.
To make adjustments to your conveyor:
- Disconnect and lockout power to the conveyor.
- Remove the chain guard.
- Check sprocket alignment by placing a straightedge across
the face of both sprockets. The faces of the two sprockets
should be square with the straightedge. If not, loosen
the set screws in one or both sprockets and adjust as necessary
to align the two sprockets. Re-tighten the set screws.
- To adjust chain tension, loosen the bolts that fasten
the motor base to mounting angles on both sides. Tighten
take-up bolts until desired chain tension is reached. Do
not over-tighten. A good rule of thumb is 1/4" deflection
in the chain between the sprockets. Make sure both sides
are adjusted the same amount to maintain sprocket alignment.
This can be measured at the take-up bolts. Re-tighten mounting
- Lubricate the chain per your maintenance instructions.
- Replace the chain guard.
- Re-connect power on to conveyor and run to test.
Caution: Never remove chain guards while the conveyor is
running. Always replace guards after adjustments are made.
Are you using the latest and most cost effective technologies
available? How do you rate against industry benchmarks in
key performance areas?
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LD Pusher is a light duty pusher designed to easily mount
to the side of many conveyor models. The LD Pusher provides
an economical solution for pushing light-weight products
off at a right angle to product flow.
- Available in Two Stroke Lengths - 7 and 10 inch
- UHMW Guides
- Aluminum Pusher Face
- Mounts to Right or Left Side of Conveyor
- Maximum Carton Weight - 5 pounds
- Minimum Pusher Centers - 6 inches
- Standard Mounting for Many Models including TA, 138 & 190-ACC, 138 & 190 NSP, 190-LR, 190-ACZ
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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!