Flexco’s innovative solutions have transformed the efficiency of large parcel-handling operations, addressing critical issues at transfer points between power curves and straight conveyors.
Before Flexco’s intervention, this operation struggled with packages getting stuck at these transfer points due to speed variations, changes in material flow direction, and differences in conveyor height or width. These issues led to frequent blockages, high volumes of returns, and a cascade of problems including damaged packaging and bottlenecks that further obstructed the flow of other packages.
An additional complication stemmed from boxes tumbling during transit, causing barcodes to move out of the electronic sensor’s line of sight. This misalignment renders the barcode unreadable, leading to more returns and requiring manual intervention by employees to reposition the boxes so the scanner can successfully read them.
Neither the original equipment manufacturer’s transfer guards nor the homemade finger guards created by the onsite maintenance crew were effective in keeping packages moving smoothly through the power curves. Other transfer point solutions weren’t feasible due to the narrow gaps and the limited space available.
After seeing a product demonstration of Flexco’s Segmented Transfer Plates, the maintenance manager was impressed and decided to test them in his power curves. These plates provide a safe and seamless transition of products throughout the sortation process, helping to reduce unscheduled downtime. The narrow-gap version of the plates was installed to address the specific challenges in this application, ensuring smooth movement through power curve gaps ranging from 38 mm to 75 mm. The system uses paired segments that lock together inside the support bar, forming a continuous span to bridge the gaps effectively.
With the installation of Flexco’s Narrow Gap Segmented Transfer Plate, the issue of returned packages within the conveyor system was eliminated. The operator previously assigned to the returns section was reassigned to more productive tasks, and package barcodes are now consistently readable, ensuring smooth and timely delivery to the next destination.
By addressing the choke points in the power curves, this solution allowed the operations team to focus on core productivity tasks rather than constantly clearing blockages. As a result, packages now move freely through the system, enabling the facility to increase output and meet its processing goals more efficiently.
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