Pallet conveyors. Automated transportation of goods

After a thorough analysis of the warehouse processes and the characteristics of the premises with a total area of 138 thousand sq. m., the KAPELOU team developed a solution to increase the efficiency of cargo handling, optimize the use of warehouse space and create a safe working environment. For this purpose, it was proposed to automate the movement of goods between 4 warehouses using roller and 4-support vertical pallet conveyors. The choice of equipment was determined by the need to store and handle pallets of different types and weights. After agreeing the concept with the customer, we designed, manufactured and installed the conveyor modules taking into account the existing warehouse processes. Successful testing of the conveyor system during commissioning demonstrated the readiness of the equipment for efficient operation in the existing warehouse conditions.

Roller conveyors: smooth movement of orders on pallets

In order to deliver pallets from 4 different warehouses, we combined the product flows. To do this, we installed roller conveyors in each gallery leading to the central warehouse. This allowed us to automate the movement of completed orders to the loading point.

The line of roller conveyors smoothly, carefully and uninterruptedly moves goods on pallets at a speed of 0.5-0.8 m/s to different areas of the pallet warehouse – receiving, storage, picking and dispatch. This helped to improve the accuracy of pallet handling and ordering, minimize the risk of damage during internal movement, and maintain product quality throughout the entire storage period.

Key features of the roller conveyors installed in the warehouses:

• total length is 300 m;
• move all types of pallets – 800×1200 mm, 1200×1200 mm, 1200×1000 mm;
• convey pallets with a load up to 1000 kg;
• robust structures are manufactured and assembled according to EN 1990, EN 1993 and European standards EN ISO 14122, EN ISO 12944, FEM 10.3.01 and 10.2.03.

The installed roller conveyors are equipped with a reversing function, which allows pallets to be moved in both forward and reverse directions. The ability to change direction quickly and without delay helps to handle more pallets with goods and save energy consumption thanks to the high energy efficiency of the variable frequency drives.

A turntable was integrated into the automation system to change the direction of pallet movement during internal transport.

The pallet conveyors have replaced a whole fleet of special equipment, speeding up and simplifying the movement of pallets with goods. Thanks to their modularity, the designs can be scaled up in the future.

Pallet lifts: reliable lifting and lowering of pallets with goods weighing up to 1000 kg

The automation of warehouse processes with KAPELOU pallet conveyors provides a comfortable and safe working environment. An important element of the project was the integration of four vertical conveyors for transport between the levels of the warehouse complex. Based on the principle of a freight elevator, the vertical conveyors smoothly and safely raise the load to a predetermined height, from where they automatically transfer it to a line of roller conveyors. The lift ensures a continuous flow of goods, speeds up their processing and increases the productivity of the storage area by optimizing the use of vertical space in the pallet storage warehouse.

The capacity of the lift in the customer’s warehouse is 100 pallets with goods per hour. Loading and unloading takes place automatically on different levels of the pallet storage warehouse.

The robust structure of the elevator is made of the highest quality steel. To ensure safe operation, the lift is equipped with safety barriers and a built-in protection mechanism at the loading and unloading points. If the risk of chain damage is detected, the lift is switched off in case of emergency, which guarantees the safety of personnel and goods.

Automation of the dispatch of orders from pallet storage warehouses

Automation based on pallet conveyors helped to speed up the client’s internal logistics processes and improve access to goods in the storage area. Thanks to the conveyors, vehicles can be loaded from pallet storage warehouses without queues from a single ramp, from where the goods are transported to the chain’s stores. For comparison, it used to take 6-8 hours to load a trailer, and after the introduction of automation, it took an average of 4 hours.

Automated pallet handling – simplified warehouse management

The KAPELOU team of specialists has integrated the roller and vertical conveyors with the Qguar warehouse management system. This solution allows Qguar to automatically receive information about the storage of goods and their movement in real time, thus ensuring effective warehouse management. Synchronization ensures the continuity and consistency of warehouse logistics – from the receipt of goods and their removal from storage, to the order completion and dispatch.

KAPELOU warehouse equipment and technologies used in the project:

• roller pallet conveyors;
• vertical conveyors for transport of pallets;
• integration with WMS Qguar.

An integrated approach based on a conveyor system allowed the customer to ensure:

• uninterrupted flow of products at all stages of processing – reception, storage, picking, transport;
• dispatch of orders from one ramp;
• increasing the speed of order picking;
• safe working environment.

The customer noted that the KAPELOU pallet conveyor systems installed in the warehouses helped to double the speed of order picking, consisting of items intended for storage in different premises. Automation has contributed to the optimal use of warehouse space, increased end-user satisfaction by speeding up the delivery of orders, and reduced operating costs.

The project clearly demonstrated how an automated pallet storage warehouse can work efficiently in the face of growing demand. We thank our regular customer Epicentr K for their trust and long-term cooperation!