Global contract logistics giant installs low-tech ball transfer unit at sorting facility
A provider of pure-play contract logistics boosted one of its key sorting lines at its Northampton facility by installing an innovative ball transfer unit solution.
The high-impact solution, designed and manufactured by Alwayse Ball Unit Solutions, has been installed at the end of a packing line for a major sportswear brand as a solution for manual sorting productivity Improvement.
The solution involves the use of 382-ball transfer units installed on a specially designed table located at the end of the pack line and connected to four conveyor lanes.
Packages exit the pack conveyor onto the ball unit table and are then pushed onto specific courier lines with no lifting by the operator necessary or use of automation equipment.
Once the boxes are queued on the specific courier line, a second operator – manning multiple conveyor lines – quickly loads the pallets.
There is no need for the second operator to look at the label or be concerned about its final destination.
The wsolution was designed to handle multiple box sizes, weights and bases, including folded with special attention paid to the smooth running of the boxes over the ball transfer units.
The system was designed, specified and installed in six weeks, with no requirement for the IT department’s involvement and minimal disruption to daily business during the installation. The solution will be in operation throughout the year, including peak periods.
Initial results suggest that with a four-person sort, the ball unit solution is able to improve productivity by 50 per cent during non-peak periods and 25 per cent during peak periods, which potentially gives an ROI of 4-6 months.
Claire Umney, managing director of Alwayse Ball Unit Solutions, says the installation solves a real productivity issue for the customer. “This is a low-cost, low-tech solution that overcomes the problem of unidirectional conveyors.
“The ball unit is omni-directional, allowing boxes to be pushed, not lifted, which leads to both productivity and health and safety improvements in sorting operations, without the need for expensive automation systems.
“We believe we have delivered a very cost-effective manual handling solution that can be designed, manufactured and installed quickly and easily.”
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