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6. After-sort Lines
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Commitment to Training
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Commitment to Training
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Features: Air Operated. 10 to 15 cpm. 23 cpm maximum. Product orientation is rotated 90 degrees Net price, $1,097 For 30 wide unit Benefits: A positive consistent divert of product. Simple, low-to-no maintenance Low cost per sort station
Commitment to Training
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Disadvantages Changes case orientation Limited sort rate Must add guarding if used in people work area Single side sorter
Commitment to Training
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Features: Air Operated. 30 to 40 cpm. 40 cpm reasonable maximum. Product orientation is rotated 90 degrees List price, $8,800 For 30 wide unit Benefits: Higher rates for 90 degree sortation Low cost per sort station
Commitment to Training
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Disadvantages High(er) cost per station Changes case orientation Limited sort rate Single side sorter
Commitment to Training
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Features: Air Operated. 15 to 30 cpm. 35 cpm maximum. Product orientation is maintained List price, $1,850 For 30 wide unit Benefits: A positive consistent divert of product. Simple, low-to-no maintenance Low cost per sort station
Commitment to Training
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Disadvantages Limited sort rate Can cause carton rotation with square boxes, especially if cartons are not aligned to divert arm. Single side sorter
Can be used for both side sorting if the products are same size
Commitment to Training
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Features: Air Operated. 30 to 65 cpm. Product orientation is maintained List price, $3,518 For 30 wide unit Benefits: A positive consistent divert of product. Simple, low-to-no maintenance Low cost per sort station
Commitment to Training
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When to use it: 30 to 45 cpm sortation systems that: Have open or closed cartons 45 to 70 cpm shipping systems that: Have closed cartons Dont require consistent label orientation Have a high number of divert stations Sortation systems that have a wide range of cartons, from small to large, light weight to heavy Sortation systems that must handle poor quality cartons, such as import quality rice paper boxes with rounded bottoms. Sortation systems with many divert points.
Commitment to Training
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Commitment to Training
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Powered after-sort lines powered sweep units provide the best control of cartons during the sort process. Slaved power sweeps are about the same cost as dense pack skatewheel sweeps, so use power if you can slave it.
Air supply. Dont starve the sort station for air. For high air use sort stations like the Autosort 4 Flat Face Sort Station you may have to restrict the number of consecutive sorts to the same station to prevent air pressure drop and erratic sort arm performance.
Commitment to Training
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Powered turns when using belt turns to connect sorters, and higher rate and/or speed systems, consider using 5 ft. inside radius curves. This will reduce cartons slinging to the outside or tipping over. After-sort sweep use a connection kit to facilitate the bolt-up and set the elevation of the sweep below the belt sorter per the instructions. You want the sweep to take over control of the carton so the belt doesnt spin the carton. Sorter drive - For the belt sorters, provide room for the 6 ft. end drive unit plus 4 ft. or 6 ft. for the automatic take up springs. A center drive unit is available if there is insufficient room for an end drive.
Commitment to Training
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Features: Air Operated. 40 to 80 cpm. Product orientation is maintained Net price, $6,105 For 30 wide unit Benefits: A positive consistent divert of product. Gentle handling of product.
Commitment to Training
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Problem Set #3
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Problem Set #3
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Sortation Devices Autosort 9 AutoRoll 30 and 90 (MDR) Pop-up Wheel Sort Station
Operation: Wheels Lift Up Between Rollers Wheels transfer product to a take away conveyor. Wheels lower before next carton
Features: 24 volt D.C. motor driven Air operated Up to 40 cpm 30 degree and 90 degree take-away units Net price, approx $4,803 For 30 wide unit Benefits: A positive consistent divert of product. Simple, low-to-no maintenance
Commitment to Training
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When to use it: Single sort point required. 10 to 40 cpm sort / divert points. When the customer does not want a swing arm sorter some people simply want a bottom type sorter When there are people working near the sorter causing safety concerns with the swing arm sorter. When case orientation after-sort is important.
Disadvantages High cost per divert Low to medium rate sort device Difficult for electric controls to make into a long multiple-divert sorter
Commitment to Training
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Features: 24 VDC or 460 VAC motor driven Air operated (Electric lift option special) Up to 35 cpm for parallel take away. Up to 40 cpm for perpendicular take away. Net price, Approx $4,447 For 30 wide unit Benefits: A positive consistent divert of product. Simple, low maintenance
Commitment to Training
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Problem Set #4
1. Which MDR right angle transfer would you suggest here, 726 or 727? 2. Who would you consult before ordering this equipment?
Commitment to Training
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Problem Set #4
1. Which MDR right angle transfer would you suggest here, 726 or 727? 726, light duty transfer based on the rate and weight of items to be transferred 2. Who would you consult before ordering this equipment? My controls vendor, to discuss how they would control this. Discrete or Ethernet? 3. Is a gap roller required here? No, based on the light weight product.
Commitment to Training
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Features: Air operated lifting action. Divert wheels are slave driven from the multi-belts. Five rows of divert wheels 30 to 100+ cpm. Product orientation is maintained
Benefits: A positive consistent divert of product. Gentle handling of product. Single or both-side sorting
Commitment to Training
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When to use it: 30 to 100 cpm sortation systems. When the customer does not want a swing arm sorter some people simply want a bottom type sorter When there are people working near the sorter causing safety concerns with the swing arm sorter. When case orientation after-sort is important.
Commitment to Training
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Notice how the divert rollers lift in the direction of flow to reduce carton skidding when diverting.
Commitment to Training
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Equipment Application: Sorters When to use it: Autosort 17 MBS90 Pop up Roller 20 to 60 cpm sortation systems. When the layout requires both-side sorting When to Use It
Advantages Low to medium rate sort device A relatively gentle sort, consistent and repeatable. 90 deg. case orientation Good device to sort cartons and totes. Single and both-side sorter Can integrate with the MB30 sort station When there are people working near the sorter causing safety concerns with the swing arm sorter. When 90 deg. case orientation is required.
Disadvantages High cost per station High cost per foot Maximum speed of 300 fp Not good for tall and/or narrow cartons at high sort rates.
Commitment to Training
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Problem Set #5
1. Use the sorter spreadsheet to price and confirm speed for the AS17 sorter.
Commitment to Training
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Problem Set #5
Commitment to Training
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Problem Set #5
1. Use the sorter spreadsheet to price and confirm speed for the AS17 sorter.
Commitment to Training
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Features: 50 to 120 cpm. Product orientation is maintained Up to 350 fpm Benefits: A positive consistent divert of product. Simple, low-to-no maintenance Low cost per sort station Divert to either side
Commitment to Training
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Equipment Application: Sorters Autosort 13 Sliding Shoe When to Use It When to use it:
Advantages High rate sort device Positive sort, Gentle, Low impact Does not change case orientation Good for poor quality cartons, totes Good for small products 50-120 CPM Sortation systems When a customer wants positive sorting of a wide variety of cartons. When you must sort to both sides.
Disadvantages High cost per foot Noise levels from high speed systems
Commitment to Training
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Features: 50 to 250+ cpm. 150 cpm dual side sorting Product orientation is maintained Up to 600 fpm Breakaway safety shoe design Benefits: A positive consistent divert of product. Simple, low-to-no maintenance Low cost per sort station Divert to either side
Commitment to Training
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Equipment Application: Sorters Autosort 20 Sliding Shoe When to Use It When to use it:
Advantages Highest rate sort device Positive sort, Gentle, Low impact Does not change case orientation Good for poor quality cartons, totes Good for small products Infinite switch positioning Networkable controls Maintenance friendly 50-250+ CPM Sortation systems When a customer wants positive sorting of a wide variety of cartons. When you must sort to both sides. 150 CPM dual side sortation!
Commitment to Training
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6. After-sort Lines
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Recirculation Line Issues: It has to run fast enough to absorb all the sort rate. How many cartons to absorb before shutting down the sorter? Lane full sensor should be set to allow room to absorb a full sorter. Needs to be long enough to avoid loop lock Typically, you have to absorb a high rate (the sorter rate) and release at a slow rate.
Commitment to Training
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Sort Rate and Case Size allows LRPE or MDR singulation mode but belt speeds exceed 200 FPM.
Commitment to Training
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Equipment Application 6. After Sort Lines Here it comes. What are you going to do with it?
1. Accumulation
6. After-sort Lines
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End-of-line operation: Manual pallet building for shipping Gravity accumulation was chosen for the shipping lines, with a belt decline to avoid the speed problem when using gravity chutes. The powered decline allowed the use of slaved powered sweep after-sort sweeps but tite-pack skatewheel sweeps were used to avoid the expense of high-speed sweeps. End-of-line operation: Pack to light operation Powered belt, powered accumulation, and then gravity accumulation / decline was chosen for the PTL lines. The skatewheel sweeps provided a slight buffer to slow-down the sort rate from 120 to ???
Commitment to Training
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12 x 12 30 x 24 24 x 24
Example 4:
End-of-line operation: Manual pallet building for shipping No-read and jack-pot line Powered accumulation was chosen for the shipping lines, the system had the height for gravity flow but the product (electronics, television sets, etc.) required controlled accumulation flow. LRPE accumulation with 10 ft. of semi-slug fill mode was used to absorb 5 cartons at the sort rate. Cartons after 5 were recirculated to avoid over stuffing the accumulation line. The 180 degree curve was converted to tite-pack skatewheel. The stop/start of the decline belt would have caused a slave power curve to stop/start with product load not recommended. The decline meters product to the pallet build gravity section. The after-sort sweep is powered because it could be slaved from the live roller.
Commitment to Training
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Example 5:
End-of-line operation: Manual pallet building for shipping Same project as Case Study 4 but actually how the system was installed. The decline gets product down to the floor area quickly. The after-sort sweep is powered because it could be slaved from the decline. Note, the sweep v-belt is pushed by the decline slave. This can create control problems and v-belt failure problems. Powered accumulation was chosen for the palletizing lines, the system had the height for gravity flow but the product (electronics, television sets, etc.) required controlled accumulation flow. The 180 degree curve is slave driven from the decline using a 3-pulley slave unit (instead of a power feeder belt) so the curve v-belt is pulled rather than pushed.
Commitment to Training
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End-of-line operation: Fluid loading, floor stack, shipping system Gravity accumulation was chosen for the shipping lines, the system had the height for gravity flow and near-by operators if a carton flow problem occurred. And, the customer needed the cost savings over powered accumulation to fit the system into his budget. A brake belt is provided to hold back the gravity accumulation and also to meter cases into the truck rather than releasing a gravity slug into the truck. Skatewheel after-sort lines are used because there was no adjacent power conveyor to slave a v-belt sweep. The tite-pack skatewheel works very well in this application, but powered sweeps are always better.
Commitment to Training
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Example 10:
End-of-line operation: Manual carton scan and sort into check/pack work stations Gravity down lines and accumulation was chosen because the sorter was up high for walk-under traffic egress. Skatewheel sweeps were used for the after-sort line. Low cost standard pattern skatewheels were allowed because of the single-size large carton. Flat-bottom chute was used because centering of the cartons for accumulation was not required.
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20
12 x 12
Maxi
Design
21 x 15
18 x 15
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Example 12:
End-of-line operation: Fluid loading, floor stack, shipping system LRSA powered accumulation was used because of the overhead location and because of consultant preference. The after-sort sweep is slaved from the powered accumulation conveyor. The 180 degree powered curve is slaved from the belt decline, otherwise slaving from the infeed live roller conveyor would have meant possibly accumulating on a constantly running curve not recommended. Even this slave-from-the-decline arrangement is not recommended since the v-belt curve will stop/start as the decline feeds the truck loading operation. The curve should have been a tite-pack skatewheel turn slightly over pitched to insure flow.
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Example 13:
End-of-line operation: Manual pallet building, pallet staging, pallet loading, shipping system Pusher sorting because of the high rate. Layout using parallel power curves required to present the carton side-label to the pallet building person on the right hand or left hand build stations. Both-side sorting allowable because of the large one-size box. Gravity flow after-sort lines used. Initial 20 ft. of pitched gravity, then level gravity to facilitate pallet build operation.
Commitment to Training
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Commitment to Training
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Equipment Application: After Sort Lines Using Gravity Pie type Chutes
Used on Autosort 4 Flat Face Arm above 45 CPM Typical Pitch 20 Degrees Available in 18 to 36 Nominal Widths 3 Deep 12Ga Frame Note: at rates of 45 cpm and higher, when using the flat face sort arm, carton rotation can occur, especially when sorting square cartons. The use of a pie chute will help straighten out the carton. The use of a trough type straight chute after the pie chute will also help straighten out and center-align cartons before subsequent accumulation. Label orientation is difficult to control due to the carton rotation.
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Typical Pitch 5 Degrees Available in 18 to 36 Nominal Widths Air Brakes can be added to control flow. Typically, the sweep is 6 wider than the system width. For the gravity after the sweep, use the same 6 wider width.
Dont forget to consider your product. Remember this project? The customer used totes instead of cartons. They came down these chutes like a rocket and onto the gravity like a freight train. Not a good thing! The chutes all had to be replaced with belt declines!
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Powered Sweep
Powered Sweep
Belt Sorter
Decline Belt
Accumulation
See Accumulation Speed Calculations. Fill at sorter rate? How many cartons to a slug? What is the Drain rate?
Commitment to Training
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