CKF are best of the bunch with their banana palletising solution for Primafruit
CKF Systems was delighted to have been chosen by Primafruit to develop a new bespoke robotic de-palletising and re-palletising system at their site in the Vale of Evesham. Primafruit is a primary supplier of a broad range of fruit. The challenge The banana inspection and packing lines within Primafruit at their Evesham facility were heavily reliant on manual labor. Imported produce, cardboard trays filled with bananas, were received stacked on pallets, typically to a height nearing 2.5m. The operation for Primafruit was to de-stack the cardboard trays, inspect the produce, and re-pack the fruit into either cardboard trays or collapsible, returnable plastic crates prior to re-palletizing and despatch to their retail customer. Primafruit wanted to automate the process at their state-of-the-art facility which is perfectly located in a central hub for agriculture and have a dedicated pack house, chilled storage, and ripening chambers. The new system was another important step in their automation journey creating a more efficient and safe working environment. Approach CKF has vast experience, designing and building robotic palletizing systems for a wide range of industries. This application demanded that the CKF team fully understand the challenges such that customized solutions could be developed to provide Primafruit with an efficient automated process. The challenges were identified as: De-stack filled cardboard trays from a pallet 2.5m high that could have an inconsistent stack form and deformed cases due to transit. Manage and deliver cardboard trays containing bananas to each inspection and re-packing station ensuring there is always an empty tray or re-useable plastic crate available at each station to enable continuous inspection and re-packing. Re-stack either cardboard or re-useable plastic crates onto the finished pallet ready for despatch. Minimize the system footprint for the efficient use of the existing floor space. For the automation to be cost-effective CKF proposed a single robot for de-stacking and re-stacking. Searches, tolerances, case quality, and stack profiles are all key elements to the success of any robot palletization. To undertake the de-stacking and re-stacking utilizing a single tool would require a bespoke design. The CKF Engineering team also understood the demands on the tool to handle two differing containers i.e. cardboard trays and plastic collapsible, re-useable crates. It was vital that the tooling developed would maintain the integrity of the bananas, without marking or causing any damage. By using a single robot cell, the system would maximize the floor space available to ensure that designated access routes for personnel and the movement of materials would be maintained. The Solution CKF, an experienced ABB value provider for over 13 years, utilized an ABB IRB 660 industrial robot system in the solution design – this dedicated palletizing robot is designed to handle a load of up to 180kg at a reach of up to 3.15m. Its low-weight upper arm, 4-axis design, and parallel rod system mean it delivers optimized speed, reach and payload. This robot is exceptionally fast making it ideal for palletizing bags, boxes, crates, bottles and more. The CKF Engineering team developed the bespoke gripper to pick either two or three cases at a time (dependent on stack orientation.). The single tool was designed to suit both de-stacking and re-stacking, together with handling two case variants of differing dimensions, location points, and material. Based on an anodized aluminum framework to reduce weight, the tool utilizes pneumatically actuated side grippers and base slide plates for transfer of the multiple case format, additionally, a vacuum assist is required to enable lifting of the product trays prior to separation from the stack. Due to the lack of conformity of the pallet stack from the suppliers to Primafruit, the CKF team developed the Robot positioning for de-palletizing using an onboard sensor array to determine the coordinates of height and stack position prior to the pick operation. Once transferred from the pallet, stack cases are transferred to and from the inspection cells on the CKF range of ZPA conveyor sections which utilises the Interroll DC platform. This perfectly matched range of controls, motor rollers, and power units enables the provision of a unique combination of conveyors for this system. This includes CKF accumulation conveyors configured to provide individually controlled zones, allowing zero pressure accumulation of the product trays and the flexibility to be configured to different sizes. The system is driven on a Rockwell platform using a compact GuardLogix 5380 safety controller with a 10” SVGA touch screen for the Operator interface. Troax safety fencing is used around the robot cell to provide the enclosure, with Leuze light guards providing protection for pallet entry and exit.
Seven deadly sins of manufacturing
Learning how to identify and prevent these sins will reduce or eliminate unnecessary waste, improve efficiency and productivity, protect profitability and cash flow, and uphold your company’s reputation. If any of these sins are lurking within your business, here’s how to identify and rectify them. Transportation Delivering products on time to manufacturing customers is essential for building vendor loyalty. However, waste created by unnecessary movement of raw materials, finished goods, or work in process (WIP) can make it difficult to meet expected shipping dates, leading to increased costs and dissatisfied customers. In addition to wasting fuel and energy costs, excess transportation can also trigger other wastes such as waiting and motion. Transportation waste often results from poor plant design, such as large distances between operations. It can also be generated by large batch sizes, poorly designed production systems, and multiple storage facilities, as well as inefficient material flows during storage, retrieval, and transfer. To prevent this kind of waste, design a sequential flow from raw materials to finished goods, don’t store WIP in inventory, and maintain consistency and continuity when assigning job priorities. Value stream mapping (VSM), a lean manufacturing technique for analyzing, designing, and managing the flow of materials through the shop floor, can be very effective in identifying transportation waste. It involves full documentation of all aspects of your production flow rather than just mapping specific production processes. The voice of the customer (VOC) can be used in conjunction with VSM to add important information. If your VOC has information critical to success that is not supported in your VSM, (e.g. customer says they want delivery in X days, your VSM says the process takes more than X days) the two documents together can guide the improvement efforts. Inventory Excess inventory is a form of waste related to the holding costs of raw materials, WIP and finished goods. In addition to driving up inventory costs, this deadly sin ties up capital, takes up space, and allows for inventory to age and obsolete. Excess inventory is a good indicator of other issues within the production process. Excess material purchasing resulting from poor forecasting and production planning is often caused by a poorly designed link between the procurement department and the manufacturing and scheduling departments of an organization. Due to a lack of visibility and an unknown future, procurement is forced to err on the side of ordering too much material. Purchasing raw materials only when needed and reducing the need for safety stock will minimize this waste. ERP Inventory software simplifies this process by tracking inventory counts with remarkable accuracy to facilitate the reduction of over- or under-purchasing. Mobile barcode scanning for inventory receiving and movement can reduce this type of waste by providing high levels of inventory visibility and control. It reduces the need for manual inventory and cycle counts, increasing the accuracy of stock on hand. Real-time inventory data improves the performance of forecasting software so purchasers know when to order more stock. Motion This deadly sin consists of unnecessary movements by employees or machines that don’t add value to the product or service. Common sources of motion waste include poor workstation layout and negligent production planning and process design. Shared equipment and machines, siloed operations, and lack of production standards can be added to this list. Motion on the shop floor can include reaching for raw materials, walking to get tools or materials, or moving finished goods out of the work area. Redesigning your shop floor to simplify the work will help reduce excess motion. In the office, wasted motion can include searching for files, sifting through spreadsheets or multiple folders to find what is needed, excess mouse clicks, and double data entry. ERP software can jettison a lot of this waste by automating processes to eliminate manual data entry, reduce paper, and simplify purchasing and receiving. Implementing 5S, a five-step methodology that creates a more organized and productive workspace can also play a role in minimizing motion waste: Sort – Keep only what you need Set in Order – Keep it organized Shine – Keep it clean Standardize – Keep it the same across workstations Sustain – Keep it consistent over a long-time horizon Waiting Wasting time waiting for materials, information, equipment, or people is considered a sin because it slows production, increases costs, and adds no value. Furthermore, it can prevent finished goods from being delivered on time – a bigger sin in the minds of customers. A major source of waiting occurs when production employees don’t know which job to be working on now and what comes up next or have not been provided with the necessary raw materials. ERP software can solve that problem by making the information directly available to machinists without leaving their workcenters and providing the warehouse with a dispatch list of jobs slated to start. To reduce this waste, use VSM to analyze the total time spent working on jobs from order to shipment and summarize the amount of time where value is not added to your product. Make the process flow as seamless as possible by creating buffers between production steps and create standardized instructions to provide consistency in the method and time required for each step. Four rules to minimize waiting waste: Automate scheduling so workers always know what to do and when. Design processes to ensure continuous or single-piece flow. Have standardized work instructions. Develop multi-skilled workers who can quickly adjust to unexpected work demands. Overproduction Overproduction occurs when manufacturing the product is required or before it is asked for. Often referred to as the “just in case” sin, manufacturers tend to use overproduction as a backup in the event of unexpected increases in demand. However, it can lead to a rash of problems, from preventing smooth workflow and increased storage costs to hidden defects within WIP. All of which require additional capital to fund excessive lead times and the production process. Strategies for terminating overproduction include: Use a pull system to control manufacturing
Semi-automated pallet shuttle technology optimizes material handling storage
For businesses seeking optimal warehouse logistics management, Steel King Industries, an OEM with extensive expertise in designing and manufacturing high-quality pallet rack systems, offers a new semi-automated technology as a turnkey solution. The pallet shuttle is a lithium-ion powered Pallet Runner™ deep lane storage system from partner Automha Americas, a pioneering pallet shuttle provider, that efficiently moves pallets in and out of high-density storage lanes, creating increased storage density in an existing space. The system is particularly suited to applications with high-volume SKUs, as pallets are loaded into the system by lift truck and transported into deep lanes by the Pallet Runner cart. Once the load is positioned, the cart returns to the front of the system to receive the next pallet. The lift truck operator travels only between load source and lane entry, and the cart does the rest. This maximizes productivity and minimizes travel distance for both product loading and unloading. The Pallet Runner is a cost-effective option for companies looking to streamline their storage processes, reduce operational costs, and ensure a competitive edge in the rapidly evolving market. The deep lanes of the system increase storage density by reducing aisles and utilizing depth space, maximizing storage capacity within the same footprint. The system moves quickly and seamlessly, enhancing efficiency, expediting pallet loading/unloading, and reducing wait time for trucks at loading docks compared to traditional forklift operations. The system can be scaled up or reconfigured with relative ease to accommodate growth or changes in product lines. With less need for forklift drivers to enter storage lanes, the Pallet Runner system reduces labor requirements and associated expenses while improving safety. “The seamless integration of the pallet shuttle technology with the pallet rack systems will offer warehouses and distribution centers increased automation, efficiency, flexibility, productivity, and safety,” said Don Heemstra, VP of Sales and Marketing for Steel King. About the Author: Del Williams is a technical writer based in Torrance, California.
Automated Micro-Fulfillment Centers (MFCs) market needs to overcome challenges to reach forecast $3.5bn by 2030
Market challenges post-Covid – including rising living costs, project delays and bottlenecks – will need to be overcome in order for the sector to flourish. Opportunities for the automated Micro-Fulfillment Center (MFC) market are growing substantially over time due to the rising demand for shorter delivery times. Providing vendors address the barriers to adoption, the MFC market is projected to grow at a CAGR of 65% from 2023 to 2030, reaching over $3.5 billion annually by 2030. According to the latest report from Interact Analysis, the market for automated micro-fulfillment centers (MFCs) has witnessed a series of challenges to adoption. However, the market opportunity remains high. To reach widespread adoption, several barriers need to be overcome. Assuming these barriers are overcome, Interact Analysis expects the market could grow to an annual revenue of $3.5 billion by 2030. Nascent stages of growth Despite initially high expectations, deploying automated MFCs has faced several challenges that fit into two categories: productivity inhibitors and hidden costs. Productivity inhibitors include integrating manually picked items, with those selected by automation proving inefficient, reducing overall system throughput. Advancements in manual in-store fulfillment software have also narrowed the ROI gap, diminishing the appeal of automated solutions. Additionally, macroeconomic factors, such as rising living costs, have also encouraged consumers to favor in-store shopping over delivery services, further dampening demand. Furthermore, hidden costs like construction delays and process refinements – along with productivity inhibitors like bottlenecks in the consolidation of manually picked items and MFC replenishment – have also negatively impacted ROI, making the adoption of automated MFCs less attractive. These barriers to adoption must first be addressed. If they aren’t, the number of MFC deployments will be lower than expected. Addressing the barriers to adoption As part of the research process, Interact Analysis identified several key strategies MFC vendors should adopt to address the previously mentioned barriers to adoption. These include sophisticated fulfillment software, flexible and scalable automation solutions, effective pricing models, and many others. To address the barriers to adoption discussed above, vendors must be able to provide expansive fulfillment software. Online grocery fulfillment is complex and involves the processing of orders, quickly. Automated MFC’s offer the capability to integrate hardware, software, and human labor to solve these logistical challenges efficiently. Flexibility and scalability are also key. Automation solution providers must be able to provide solutions that cater to different facility sizes while ensuring that they enhance the ROI for retailers. The level of complexity of the solutions must also be considered. Retailers want to be able to install the solution without the need to spend time and money training workers. Many automation providers have successfully done this by having user-friendly interfaces installed on the technology. What does the future hold for MFCs? Overall, the market for Automated Micro-Fulfillment Centers (MFCs) is projected to experience significant growth, with a forecast compound annual growth rate (CAGR) of 65% from 2023 to 2030, reaching a market size exceeding $3.5 billion annually by 2030. In 2024 alone, Interact Analysis predicts that grocers will spend $18.5 billion on store labor for online order picking. By comparison, the total warehousing sector will spend ~$180 billion on labor, meaning that grocery in-store fulfillment labor cost equates to 10% of the total warehouse labor costs. The market is witnessing a bifurcation, with smaller sites for convenience orders and larger sites for weekly shop orders. As a result, technologies such as mobile AS/RS, shuttle AS/RS, and ultra-high-density storage systems are expected to play a significant role in fulfilling weekly shop orders, while nanofulfillment solutions are primarily going to be used in the fulfillment of convenience orders. Labor is generally still being used for manual in-store picking but the total addressable market for MFCs through localized fulfillment is increasing. Overall, the e-commerce market value for localized fulfillment is expected to increase from $1.9bn in 2023 to $4.4bn in 2030. This is mainly driven by the grocery segment but also other verticals such as healthcare and general merchandise due to the demand for shorter delivery times. Rowan Stott, Research Analyst at Interact Analysis, comments: “The market is in its early stages of growth, with several barriers to adoption in the MFC industry that haven’t been addressed yet by vendors. We believe that addressing these will be the most important factor in determining future growth. “Overall, the automated MFC market is poised for substantial growth, driven by the increasing demand for localized fulfillment and advancements in automation technologies. As major retailers continue to invest in these solutions, the market is set to rapidly expand, offering significant opportunities for vendors and stakeholders in the industry.” About the report Over the years, we’ve developed and refined our view of what micro-fulfillment is and how to define it. We’ve come to the conclusion that micro-fulfillment is less about the size of the facility, but rather more about the radius of delivery. As such, the scope of this report is constrained by delivery radius, rather than facility size. In addition to providing a wealth of granular market data, this report will also explore what the biggest barriers limiting the uptake of micro-fulfillment centers, along with the key attributes that retailers are looking for when selecting an automation partner.
Electric hoist leaves large distillery in high spirits
The world’s largest producer of spirits is now benefiting from a turnkey package of three Italkrane ATEX-rated electric chain hoists supplied by Hoist & Winch Ltd. Operational within a new extension of the Scotland-based distillery, the 2-ton swl (safe working load) hoists raise and lower sealed vessel lids and baskets containing raw materials used in the production of gin. Among the challenges of this demanding project was a restriction in the overall height of the new building due to local planning laws. In turn, only limited headroom is available for lifting operations over the vessels. Critical for the application, therefore, was the specification by Hoist & Winch of Italkrane YY series electric chain hoists featuring a low-headroom design. The ATEX specification of the hoists is necessary due to the vapours and fumes produced in the manufacture of alcohol-based products. Italkrane YY series electric chain hoists feature an Ex d electrical enclosure design to contain any explosions and stop flames, sparks and hot gases from escaping. Full anti-spark features are in place for all components subject to sliding friction, including the brass trolley wheels. Also present is a non-sparking load hook, brass anti-tip device and polycarbonate pendant control ensuring explosion protection up to Zone 1 II B T4 classification. The power supply to each hoist unit is via a festoon cable track system complete with sliding trolleys and support arms clipped to the top flange of the hoist runway beam. Each hoist unit also features an Italkrane heavy-duty geared top/bottom limit switch and friction-type slipping clutch overload protection device. “Although we provide a full spectrum of lifting equipment services, Hoist & Winch is particularly at home supplying equipment for demanding industries, including the distillery sector,” explains Hoist & Winch Director Andy Allen. “We have extensive knowledge of this industry, where our quality of service and flexible approach ensure the highest levels of customer satisfaction.” Due to the critical nature of the project and the risk of explosion throughout the high-risk site, it was clear that very stringent planning and close monitoring of working practices would be necessary at all times. In addition, the site work was subject to Construction Design and Management (CDM) Regulations, supported by a requirement for all site engineers to hold a valid CCNSG Safety Passport/CSCS competency certification. Installation took place over seven days, with a Hoist & Winch CompEX-certified electrical installation engineer completing all connection work. The load testing of each hoist unit and complete runway beam took place using a dynamic test load of 2t + 125% proof load. Additional functional testing using the vessel lids and raw material baskets proved system functionality in line with customer requirements. Following the issue of a LOLER (Lifting Operations and Lifting Equipment Regulations) Thorough Examination Report for all installation work, Hoist & Winch provided on-site training for the distillery’s operating personnel. Although providing the optimal solution for this large distillery, Italkrane ATEX-rated electric chain hoists are also suitable for many other applications requiring safe lifting operations in explosion risk environments. In addition, Hoist & Winch can offer ATEX wire rope hoists for longer lifting tasks, heavier loads up to 50t swl and higher duty applications.
Kito Crosby announced significant investment in Peerless chain manufacturing equipment
Kito Crosby, a global leader in the lifting and securement industry, proudly announces the completion of a major investment at its flagship manufacturing site of Peerless branded products in Winona, Minnesota. The multi-year, multi-million-dollar, project involved the design, installation, and startup of an advanced continuous plating system utilized in chain production. This state-of-the-art system adds a unique and proprietary coating to a chain that prevents rust and corrosion to our already world-class product. Designed to further enhance product quality and employee safety, the new plating system incorporates new features, such as automated monitoring and increased air handling systems. “This line was designed with our customers and team members in mind,” said George Kosidowski, President of Peerless. “The investment will enhance our internal processes, which will improve our service levels to customers and scale our operations for increased demand.” The Winona plant, like all Kito Crosby manufacturing facilities worldwide, is heavily vertically integrated, with a Peerless chain manufactured in the United States from raw material to finished product on site. A special ribbon-cutting ceremony was held in July with Winona team members and Kito Crosby leaders, local dignitaries, and the International Association of Machinists & Aerospace Workers (IAMAW) leadership. Continuous plated chains are used across multiple industries, including food processing, cargo control, trailer safety, and hardware.
BSL Battery-Industrial cutting-edge technology and unparalleled expertise revolutionizes the material handling battery industry
Providing automotive-grade modular lithium battery systems that are transforming the material handling industry, BSL Battery – Industrial is at the forefront of innovation. With over 10 years of combined experience in manufacturing renewable energy and battery systems, BSL Battery – Industrial has revolutionized the market with significant investment, lean manufacturing capabilities, seamless supply chain integration, a team of design experts with 180 years of experience in the lithium battery industry, and a commitment to customer service. The purpose of this in-depth article is to examine how BSL Battery – Industrial’s lithium forklift batteries are different from other batteries on the market, and how the company ensures their durability and longevity. Through continuous innovation in lithium-ion batteries, BSL Battery – Industrial has achieved rapid growth and numerous milestones since its founding in December 2012. A professional R&D team of more than 100 engineers led by PhDs with an average of more than 20 years’ experience in power electronics, battery management systems, and energy storage inverters is established by BSL Battery – Industrial, which spends over 6.2% of its revenue on R&D in the field of new energy innovation every year. Our R&D team focuses on developing new energy system solutions, including power electronics, battery state-of-charge algorithms, system hardware and software design, and battery module and battery pack development. BSL Battery – Industrial focuses on innovation and quality and meets and exceeds international and North American performance, reliability, and safety standards. With more than 60 patents and awards, BSL Battery – Industrial has a comprehensive intellectual property protection system. BSL Battery – Industrial has always been proud of its strong R&D and manufacturing capabilities which have led to the company standing out, gaining wide recognition in the industry, and consolidating its position as a recognized leader in lithium-ion forklift batteries with a leading market share. The R&D team will continue to adhere to the principles of innovation and quality first despite these achievements. Recently, BSL Battery – Industrial is pleased to announce that our B-LFP48-615MH, B-LFP48-460MH, andB-LFP36-820MH lithium battery models have been certified by UL Solutions and tested to Revision 3, the latest and most stringent version of the UL safety standard! We are committed to excellence in product safety, design, and manufacturing. Together, we can make material handling safer and more efficient! There are many advantages to lithium-ion batteries, including a strong discharge, a stable voltage curve, faster lifting and driving speeds, and a lower cost of ownership. Compared to lead-acid batteries, lithium-ion batteries have a significantly longer service life, making them cost-effective and sustainable. An ideal choice for individuals and businesses seeking reliable and efficient power solutions, it is fast charging, maintenance-free, environmentally friendly, and operates at a wide range of temperatures. Battery – Industrial pioneered the transition from lead-acid batteries to lithium-ion batteries and from fossil fuels to electricity. With its automotive grade lithium batteries, BMS, and other accessories, the company offers a wide range of solutions, including industrial lithium batteries for the material handling industry. As the first supplier in the industry, BSL Battery – Industrial offers industrial lithium batteries from 24V – 768V and 52Ah – 2000Ah for heavy forklifts, multidirectional forklifts, and GSE. It uses LiFePO4 chemistry in its batteries to provide unmatched quality and reliability for electric forklifts, which outperforms other lithium-ion solutions in every aspect. With a design life of up to 10 years, 8 years or 12,000 hours warranty, fast charging capabilities, lightweight construction, longer charge retention time, easy installation and a range of battery options to suit different vehicle models, BSL Battery – Industrial’s LiFePO4 batteries are long-lasting and stable. Aside from offering greater chemical and thermal stability, BSLBATT® LiFePO4 batteries also include multilayer protection against water infiltration, acid spills, corrosion, and contamination that could damage the battery and put the user at risk. By eliminating routine maintenance and reducing costs, the transition from lead-acid to lithium-ion batteries is seamless. The BSL Battery – Industrial product line continues to improve. BSLBATT’s latest generation B-LFP48-460MH battery goes one step further with a continuous discharge current of 600A, a maximum discharge current of 1200A, and a peak discharge current of 1800A, allowing for faster acceleration and higher speeds. Hard-working Class I, II, and III forklift batteries that meet the gold standard. As the company continues to refine its battery systems and explore new applications, it remains committed to expanding its global presence. BSLBATT has established a global network with manufacturing centers in China, subsidiaries in the United States, Netherlands, Turkey, South Korea, Mexico and South Africa, established successful partnerships with many well-known brands, and supplies forklifts from various brands to more than 200 dealers. More than 10 forklift manufacturers provide battery communication matching, including Toyota, Hyster-Yale, Combilift, Raniero, Clark, HELI, Xilin, Crown, Doosan, HYUNDAI, etc. Its success on the market can be attributed to all these efforts. The global sales and service network system enables the company to ensure seamless supply chain, timely supply, worry-free aftersales service and responsive technical support for warehouse managers of material handling who are looking to upgrade their power solutions, so that the company maintains its position as a trusted and preferred supplier of lithium batteries for material handling applications. BSL Battery – Industrial will continue to promote the energy revolution as a pioneer in the lithium-ion battery market to create a brighter and more sustainable future. BSL Battery-Industrial has gained good recognition in many markets, including China, ASEAN, Australia, South Asia, the Middle East, America, and Europe. To enhance its competitiveness in these regions, BSL Battery-Industrial is actively seeking local distributors and partners. Feel free to contact our representatives at inquiry@bsl-battery.com or 0752-2819-469! Visit lithiumforkliftbattery.com for more information about BSLBATT.
How to choose the best battery system for your forklift
Material-handling electric vehicles use two types of batteries: lithium-ion (Li-ion) and lead-acid batteries. The main deciding factors when choosing the right battery for your forklift are maintenance, price, efficiency, sustainability, application, and TCO (total cost of ownership). With so many options available, choosing the best lithium-ion system for a forklift can be a challenge. Here’s a comprehensive guide to help you understand the considerations and choose the perfect forklift power solution. Assess your power needs Consider your power needs before diving into battery systems. With the right battery for your equipment, you can maximize your organization’s efficiency and save money. Estimate their power consumption (in watts) and average daily usage hours. Our expert sales engineers can assist you in determining your usage. As a result of this assessment, you will have a clear understanding of your energy needs and will be able to choose a battery system that meets your requirements. Discover the types of batteries Lead-acid and lithium batteries are the two main types of forklift batteries. Here are some pros and cons of each type: Batteries made of lead acid have the shortest lifespan, the lowest depth of discharge, the heaviest weight, and the most frequent replacements. In traditional lead-acid batteries, there are two types: flooded lead-acid batteries (FLA) and sealed lead-acid batteries (SLA). Compared to FLA batteries, SLA batteries require less maintenance, such as checking the water level on a regular basis. Compared to traditional lead-acid batteries, absorbent glass mat (AGM) batteries offer lower maintenance costs and slightly better performance in cold temperatures. Lithium batteries: Lithium-ion batteries offer high energy density, lightweight design, and long life in forklift power systems. Lithium batteries have a lifespan ten times longer than lead-acid batteries. Despite their higher cost, lithium batteries charge faster, discharge deeper, and have a longer cycle life than lead-acid batteries. Over time, lithium batteries can save significant amounts of money because they don’t need to be replaced as frequently as lead-acid batteries. In addition to having greater power and energy capacity, lithium batteries also take up less space than lead-acid batteries. Additionally, they do not emit toxic fumes, making them safer in a wider range of environments. Moreover, not all lithium batteries are the same. Compared with lithium cobalt-based battery chemistries like NMC, LCO, and NCA, lithium iron phosphate batteries like the BSLBATT are the most environmentally friendly and non-toxic. Factors to consider It would help if you considered the following factors when choosing a battery system for your forklift fleet: Capacity： The capacity of a battery is measured in ampere-hours (Ah), watt-hours (Wh), or kilowatt-hours (kWh). A battery’s energy represents the power it can deliver over time. Ensure your battery system has enough capacity to meet your daily energy needs, as well as some buffer in case of unexpected circumstances. Lead-acid batteries often have a “rated” capacity that is much higher than their actual or usable capacity. The reason for this is that lead-acid batteries cannot be discharged more than 50% at a time, unlike lithium batteries, which can be discharged to around 100%. Cycle life： Battery cycle life is the number of charge and discharge cycles a battery can withstand before its capacity is greatly reduced; it is important to understand this, especially for long-term forklift users. Lithium batteries have a longer cycle life than lead-acid batteries, making them an affordable choice over time. BSLBATT lithium batteries cycle 3,500 times or more, and higher discharge rates have little effect on cycle life. Lead-acid batteries, however, are generally only capable of 300-500 cycles, as higher discharge levels will significantly reduce their life span. Size： Depending on the type of lift equipment and its intended use, weight, size, and voltage can vary greatly. For different types and sizes of electric vehicles, voltage options such as 24V, 36V, 48V, 80V, 96V, and 144V are available. Understanding your vehicle needs is therefore essential to selecting the right vehicle. Recharge：Your business’ efficiency depends significantly on how quickly your vehicle can charge, and how long it takes to charge. Lithium-ion batteries, for instance, charge faster and easier than lead-acid batteries. The charging process for lead-acid batteries requires a dedicated space with ventilation and temperature control, whereas lithium-ion batteries can be charged on the spot. Maintenance：How you maintain your vehicle plays a major role in choosing the right forklift battery. You should consider factors such as battery life and watering systems when making your decision. Lead-acid batteries require a watering system to function at maximum capacity, while lithium-ion batteries are sealed and do not require one. In addition to providing: Safety： Better value for money, lithium-ion batteries last longer and have more cycles than lead-acid batteries. Temperature performance: Keeping your team safe and minimizing workplace risks should always be a priority for every organization. Lead-acid batteries contain toxic sulfuric acid, which can cause spills when adding water, overheating, gas release, and health risks associated with old or corroded batteries. On the other hand, lithium-ion batteries are sealed, eliminating acid spills, corrosion, sulfation, and contamination risks. Cost: You should choose a battery system that will perform effectively in a wide range of temperatures you may encounter during your travels. As an example, BSLBATT’s Cold Storage Series lithium batteries can charge at temperatures as low as -35°C. Choosing the right battery for your fleet is always influenced by price. Lead-acid batteries are often thought to be cheaper than lithium-ion batteries, but this is not true. Long-term, lithium-ion batteries are much cheaper than lead-acid batteries. In addition to not requiring water maintenance, lithium-ion batteries have a longer life, require less energy, and require less time to maintain, making them a more cost-effective investment than lead-acid batteries. Lithium-ion forklifts with full integration Currently, BSL’s lithium batteries are compatible with a variety of Toyota, Hyster & Yale, CLARK, Combilift, Heli, and Raniero forklifts designed specifically for fully integrated lithium-ion power. High-capacity electric forklifts reduce emissions, fuel consumption, and maintenance costs while providing ICE-like performance. You should carefully consider your power needs, battery type, capacity, cycle life, charging source, size, safety, maintenance, temperature performance, and cost when choosing a battery system for your forklift. When you evaluate these factors and conduct thorough
CP&A advises on container crane procurement peer reviews
Casper, Phillips & Associates Inc. (CP&A) has delivered a presentation to port authorities titled, ‘Peer Review of Container Cranes’, to assist in future procurement processes. CP&A offers a wide variety of services, including specification, design, manufacturing review, modification, and accident investigation; and it is well-positioned to remind terminal operators and fellow stakeholders of the risks involved with container crane procurement. Including transport and offloading in the peer review scope is a good way to manage some of these risks — but that’s just the start. Richard Phillips, mechanical engineer at CP&A, said: “The procurement process for container cranes is somewhat unique and presents many challenges. Unfortunately, some procurement decision makers believe buying container cranes is the same as acquiring any other piece of equipment, such as a forklift or a company van.” As should be unanimously accepted by crane manufacturers, a peer is someone with approximately equal qualifications to the design team. While there is no universal set of criteria as to what makes an engineer a peer, a good starting point is professional licensure and relevant design experience in the appropriate disciplines. The team should have an expert in the prevailing hazards such as high wind, seismic, or other location dependent hazards. A peer review is when a neutral third party checks the design for compliance with the performance specification. A performance specification states what the crane needs to do — rated load, hoist and travel speeds, operating wind speed, etc. — but it does not specify how the crane manufacturer needs to meet the specification. Importantly, a design review is about compliance; it is not about the design reviewer’s preference for how he or she would have designed the crane. There is a level of professionalism expected for design reviews. While there will always be debate, comments that are not backed up by analysis, specification, or code requirements should be avoided. Phillips said: “It’s a big red flag if a large number of comments are generated without supporting calculations or citations of specification requirements. It’s not constructive for the designer to have to refute a large volume of comments that may not be contractually required or may be speculation since they are not supported by calculations. The reviewer should be performing enough analysis to back up their comments.” Custom port equipment Container cranes are custom designed to meet the unique requirements of each port. Some of these requirements may include being in a hurricane or earthquake zone; exposure to extreme temperatures; or proximity to other geological hazards. Sometimes a container terminal is located near an airport, or a crane may need to pass under a bridge during delivery, resulting in height restrictions. A naval architect provides the sea states and predicted voyage motions for the designers to analyze and brace the crane accordingly. The crane manufacturer owns the cranes until handover. Some crane manufacturers own their own fleet; others subcontract this work. It can be beneficial for the design reviewer to check the voyage bracing prior to shipping. There are other operational considerations, such as where hatch covers are stored; the use of dual trollies; and how many containers the crane can lift: single 40 ft., twin 20 ft., tandem 40 ft., quad 20 ft., etc. All things considered the planning phase has great variance. Sometimes it starts at the wharf design stage, other times the wharf is already designed, and existing cranes are being replaced. Depending on the level of customization, once a crane is awarded, it can be up to three years before delivery. Phillips, who himself conducts peer reviews of contractors’ crane designs, including some of the largest container cranes in the world, pointed to CP&A’s crane base anti-seismic isolation system (BASIS), which is built on nonlinear time history analysis (NLTHA) and can protect a crane’s main structure from damage even in contingency level earthquakes. “We are always improving our software,” said Phillips. “Our crane analysis software can be thought of as a custom workbench specifically made for cranes. There is a much larger market for buildings and bridge design, so the commercial software packages tend to focus on larger markets such as those [see below]. That led CP&A to create our own crane code-checking software. One example is that we have incorporated wind tunnel test data into our pre-processor, which develops the wind load forces on a crane. Obviously, a commercial building will not have integrated wind tunnel data for container cranes.” Cranes are significant structures Interestingly, due to the geological and environmental hazards, cranes should be treated more like bridges and skyscrapers instead of mass produced cars and airplanes. However, for cars and airplanes, there are crash tests and full-scale testing, which is impractical with cranes. ASCE 7-16 1.3.1.3.4 covers minimum design loads and associated criteria for buildings and other structures; this particular clause covers peer reviews for significant structures. Phillips added: “When you start thinking about how bridges, stadiums, and skyscrapers are designed it starts to become clear. For significant structures the [AISC 7] code requires a peer review. Are cranes significant structures? In our opinion they are; however, it is up to the local jurisdiction to make that decision.” Even at the time of going to press, CP&A was wrapping up peer review and procurement assistant projects related to rubber-tired gantry, rail-mounted gantry, and ship-to-shore cranes. Are your procurement processes for these hulking container cranes up to standard?
Vertical reciprocating conveyors elevate AGVs and AMRs to new levels of efficiency
Vertical reciprocating conveyors (VRCs) act as the pivotal link between two major trends in warehouse operations that are dramatically increasing efficiency and profitability: Mobile Robots — The widespread adoption of Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) is transforming the horizontal movement of materials across facilities, revolutionizing logistics and material handling processes. Vertical Space Utilization — Driven by the pursuit of logistics efficiency, along with escalating real estate costs and last-mile distribution demands, warehouses and production facilities are optimizing “cube space utilization” by expanding upwards rather than outwards. Vertical reciprocating conveyors seamlessly integrate the horizontal and vertical material handling processes, facilitating the smooth automated flow of material in three dimensions. These flexible and compact systems can be incorporated into a wide variety of layouts and serve a multitude of different applications. Combining VRCs with mobile robots and other manual and automated equipment often represents the most efficient, safest, and cost-effective solution for accessing taller racking, pick modules, mezzanines, and multiple floor levels, in virtually any type of warehouse or production environment. Rapid Adoption of Mobile Robots AGVs and AMRs are revolutionizing logistics across many industry sectors. In factories, these technological advancements automate material handling and assembly line tasks. This not only boosts production rates but also improves workplace safety by taking over hazardous or repetitive tasks from human workers. Automated Guided Vehicles adhere to predetermined paths, whereas Autonomous Mobile Robots employ sophisticated sensors and artificial intelligence for flexible navigation. AGVs, with their lower initial costs, are sometimes preferred by production and packaging operations in obstacle-free routes where predictable timing of material delivery is paramount. Conversely, AMRs offer unparalleled adaptability in dynamic and chaotic settings, making them ideal for large warehouses and distribution centers. Mobile robots are crucial to the advancement of Industry 4.0, boosting efficiency, flexibility, and automation within manufacturing landscapes. Their capacity for autonomous navigation and task execution across diverse scenarios renders them indispensable in the drive towards more intelligent and interconnected factory ecosystems. In warehouses, the impact of these robots is even more visible and transformative. Several factors are driving the swift adoption: E-commerce Growth: As E-commerce continues to experience explosive growth, with next-day-delivery expectations and direct-to-consumer marketing models, AGVs and AMRs are key to meeting the demand for quicker order fulfillment and inventory management. Complexity of Modern Distribution: The modern warehouses and distribution centers need to rapidly evolve from classic distribution models to an omni-channel model with the agility to pick case packs, fill retail store orders, pick and pack single consumer orders, and process customer returns and product refurbishments. Labor Shortages and Rising Costs: With ongoing labor shortages, particularly in logistics and manufacturing, AGVs and AMRs offer a solution by automating repetitive tasks. Technological Advancements: Enhanced sensors, AI, and better batteries have made AGVs and AMRs more adaptable and efficient, capable of performing complex tasks autonomously. Safety and Efficiency: Compared to forklifts and manual material handling equipment, AGVs and AMRs improve workplace safety and operational efficiency, handling hazardous tasks and operating 24/7 with precision. Vertical Cube Utilization Two to three decades ago, distribution centers typically featured clear heights of 24 to 32 feet – the vertical space from the floor to the ceiling. Today, driven by the scarcity and increased costs of land, especially near urban centers, and advances in fire protection and material handling technology, the industry standard for clear heights has shifted to 36 and 40 feet, with demand growing for even taller structures. The shift towards taller buildings is also fueled by the rapid growth in multi-level facilities, specifically designed to optimize last mile distribution, accommodating the increasing demand for faster and more efficient delivery systems in densely populated areas. Leveraging the “vertical cube” not only maximizes storage but also streamlines operations, improving material handling, increasing productivity, and ensuring safety without necessitating horizontal expansion. The utilization of upper levels also frees up prime dock-level real estate for crucial shipping, receiving, or re-packaging processes. Furthermore, the concept of cubic utilization in warehouse and factory design marks a significant shift towards sustainability and energy efficiency. By maximizing cubic space while minimizing the square footage of the building’s exterior envelope, facilities significantly reduce HVAC costs. This approach not only lowers initial investment in land and construction but also yields long-term savings in maintenance, operations, and even property taxes. VRCs are Ideal for Automated Material Handling The symbiotic relationship between these two trends — mobile robots and the utilization of vertical space — mediated through Vertical Reciprocating Conveyor technology, exemplifies how the strategic adoption of advanced automation technologies and space utilization concepts can revolutionize warehousing and manufacturing. A VRC functions like an elevator, with one fundamental difference — VRCs are intended to move material loads, not people. They are regulated as a conveyor (under ASME B20.1) and not people-moving elevators, making them less costly to install and maintain than an elevators. VRCs have an enclosed platform that prevents loads from falling as they are lifted and lowered. This makes them far safer to operate than forklifts or scissor lifts. VRCs safeguard employees from injuries incurred while transporting items on staircases and deter the misuse of forklifts beyond their safe mast lift height limits. Flexibility VRCs are a versatile solution that can be installed next to mezzanines, in existing elevator shafts, or through floors, and they can also be installed outdoors. Vertical Reciprocating Conveyors (VRCs) stand out for their exceptional versatility and adaptability, opening a myriad of automated material handling opportunities. They seamlessly integrate with mobile robots and automated conveyor systems, or they can be manually loaded and unloaded. AGVs, AMRs and driverless forklifts can travel with the load on the VCR and continue travel when they arrive at the destination floor. Alternatively, they can efficiently transfer loads onto the VRC at one level, and then another system —whether it’s another AGV, AMR, or a different automated or manual material handling method — can take over at a different level. Furthermore, VRCs can effortlessly connect with automated horizontal conveyor systems, facilitating the smooth flow of
AGV wireless evolution
Discover how HMS Networks’ wireless expertise and Anybus products took Mercedes-Benz’s Automated Guided Vehicle (AGV) installation to the next level. When Mercedes-Benz wanted to expand its AGV installation, they called HMS. HMS provided the wireless expertise, products, and hands-on support to ensure the AGVs moved efficiently and safely around the factory. Mercedes-Benz Mercedes-Benz, a globally recognized automotive manufacturer, is renowned for its innovative technology, craftsmanship, and luxury design. At their state-of-the-art automotive factory in Ludwigsfelde, over 70 AGVs move automotive parts to the assembly line. These AGVs transport everything from heavy engines to smaller electronics across distances ranging from 300 to 800 meters. Each AGV is equipped with an onboard Programmable Logic Controller (PLC) from Siemens or Schneider Electric, which ensures their efficient and safe navigation. Good communication is key Guiding the AGVs effectively relies on good communication between the AGVs and the factory’s control system. This communication enables the factory to track the AGVs’ whereabouts, cargo, and real-time status. Mercedes-Benz’s previous AGV system used Bluetooth technology and HMS’ Anybus Wireless Bolt and Anybus Bridge products. However, they wanted to improve the system’s efficiency and be able to comply with the Machinery Regulation (EU) 2023/1230, which becomes mandatory in January 2027. Maximilian Lichan explains: “While Bluetooth worked well, we now want to enhance our AGV system to support higher throughput, fast roaming, and lower latency. We also need to comply with the soon-to-be mandatory EU safety regulations. Equally important, we want the equipment and experts from the same company, and we want them to come onsite, install the equipment, and verify that everything works”. Time to see how HMS helped implement a wireless system to meet the needs. HMS wireless experts pave the way Mercedes-Benz provided key information, such as floorplans, to HMS’ wireless experts. Using this information, HMS first conducted a predictive site survey to determine the optimal placement and number of access points required. HMS then visited the factory to verify the accuracy of the survey and make any necessary adjustments. Mercedes-Benz used the updated predictive site survey to install the required power outlets and network cabling. Once the required infrastructure was in place, HMS returned to install and configure the Anybus Wireless products before verifying that the installation worked as planned. Anybus wireless products The wireless infrastructure uses Anybus Access Points powered by Anybus PoE L2 Managed Switches, with an Anybus Wireless Bolt II mounted on each AGV. The Anybus Wireless Bolts handle communication from the AGVs to the traffic control system and connect to the 12 different access points in the factory’s ceiling. As an AGV moves out of range of one access point, it transitions to the next, ensuring uninterrupted communication. A critical aspect to the project’s success was the utilization of the 5GHz frequency band, while the Bolt II’s similarity to its predecessor also simplified the installation. Maximilian explains: “We wanted to use the 5GHz frequency band where we have four dedicated channels that didn’t interfere with our existing systems. It was also convenient that the Bolt II fits in the same hole as the original Bolt”. The results With the wireless expertise of HMS and their Anybus Wireless products, Mercedes-Benz successfully achieved its goal of efficient and safe transportation of goods within the factory. Maximilian happily reflects on the outcome: “Everything worked as we hoped. The connection is very stable, and we are now able to comply with the safety machinery regulation. The support for more bandwidth has even allowed us to manage and configure the AGVs remotely, which, while not a key objective is a nice bonus”. Finally, what are your tips to users who are thinking of going wireless? “A key factor for us was that HMS was on hand to design and install the wireless infrastructure. That was important for us. We wanted to have wireless experts onsite to ensure that everything went smoothly. We’re not wireless experts, HMS is. We make cars, which you probably already know,” Maximilian adds with a smile.
TIA launches 5 ways logistics leaders can harness AI successfully
The Transportation Intermediaries Association (TIA) released a new white paper titled Transforming Freight Logistics in the Era of Generative AI. The paper covers the five ways logistics leaders can harness AI to scale efficiency, security, and growth. “AI is forever changing the world as we know it,” said Anne Reinke, president & CEO of TIA. “While many are scared of the future, we feel that the 3PL industry can use AI strategically to work more efficiently, leading them to spending more time on relationship building with customers and carriers.” The latest white paper from TIA covers the five key areas that AI can help business run more efficiently: data synthesis and insights; front-end automation; identifying potential fraud on web-based platforms; customer service; and ethical concerns and governance. The white paper concludes by stating AI is transforming logistics companies’ operations, from synthesizing data and generating insights to automating processes and detecting fraud. As with any transformative technology, there are ethical considerations and governance challenges. Organizations must establish clear guidelines and expectations to ensure responsible AI deployment while safeguarding against potential vulnerabilities. Ultimately, the successful adoption of AI in freight logistics hinges on balancing technological innovation with human expertise. By harnessing AI as a force multiplier rather than a replacement for human labor, logistics companies can empower their workforce, improve customer service, and stay ahead of the curve in an ever-evolving industry landscape. Transforming Freight Logistics in the Era of Generative AI
Paper and Pulp case study: BSLBATT lithium battery helps KALMAR
Do you work in a paper or corrugated packaging plant? Are you looking for a solution that powers your workload? Historically, the paper and pulp industry uses diesel forklifts. This is mainly because this industry requires higher equipment capacity. Although it was once a diesel-focused industry, we are pleased to announce that the KALMAR ECG80-6 electric forklift can replace a diesel engine. Thanks to the unique lithium battery solutions of our agent IIB located in the Middle East. This is especially true in terms of higher capacity and longer operating time, electric forklifts equipped with our BSLBATT B-LFP80-1120MH model lithium battery can be compared to Internal combustion engine (ICE) equivalents to do this better, if not better. Results: Check out the impressive results recently achieved by a large customer in the paper industry using a KALMAR® ECG80-6 heavy-duty forklift equipped with BSL lithium batteries to electrify their material handling equipment. This customer was interested in the BSLBATT® 3.0 range of forklift lithium batteries and active cooling technology that would not only meet the energy needs and uptime required to convert to an electric lift but would also do so at a lower TCO than any other energy source in the industry Make the switch! Enable safer and more efficient fleet management. We are delighted to contribute to their efficiency and sustainability goals. Together we are shaping the future of energy solutions for the pulp and paper industry! Contact us to learn how BSL Battery – Industrial can improve the efficiency of your operations! Here are a few reasons why you should choose BSL lithium batteries for your paper industry’s material handling needs: The newly developed BSLBATT lithium battery makes electric forklifts a more viable alternative to diesel vehicles “Both the wood and paper industries are pushing hard to switch to electric trucks equipped with BSL lithium batteries. All the major players in Europe are doing this and there is no turning back. Over the past five years, our heavy-duty forklift lithium battery sales have doubled, and the growth rate is accelerating,” saidTracy Shen, BSLBATT EMEA Territory Manager. While environmental considerations come first, for some companies the cost savings of switching to electric trucks are also a factor. For example, many pulp and paper companies generate electricity. Additionally, because of electricity, they can drive down energy prices so that their hourly cost is only one-tenth the cost of old diesel. “Of course, in some countries, such as the United States, diesel is still very cheap and the savings are not yet as substantial,” adds Tracy Shen. Whatever the reasons why companies make the switch, one thing is for sure, the number of heavy-duty lithium battery forklifts will only increase. Demand is increasing around the world. BSLBATT is at the forefront of this development with its revolutionary lithium-ion batteries and more than 10 years of electrification experience. “We are currently cooperating with dealers of Toyota, Yale-Hyster, Linde, Taylor, Kalmar, Lift-Force, and Raniero heavy-duty forklift brands. Customer feedback shows they are amazed by BSLBATT lithium-ion batteries’ advantages. BSLBATT’s lithium batteries are completely Meet customer expectations,” said Tracy Shen. “ANOTHER IMPORTANT FACTOR IS THAT BSLBATT can now supply lithium batteries for heavy-duty forklifts weighing up to 18 TONES, INSTEAD OF JUST THE 5-6 tons we previously supplied.” Charging is made easy Tracy Shen says IIB began importing forklift lithium batteries to BSL three years ago and selling them to local forklift dealers. It also provided after-sales services. “The most obvious benefit is that it doesn’t require a specific charging room like lead-acid batteries, but can be charged at shorter intervals throughout the day. This way you can use the truck all the time without planning breaks to recharge the batteries. They can be recharged during a fifteen-minute coffee break,” he said. Companies investing in upcoming factories are already planning for electric trucks and ensuring there are places to charge them at convenient times and locations. High durability and minimal maintenance Compared with lead-acid batteries, BSLBATT’s patented lithium-ion batteries have several advantages. First, there is no need for multiple batteries in multi-shift operations. One is sufficient as it can be charged during the shift. Second, BSLBATT batteries have a service life of up to 4,000 times, compared to 1,500 times that of lead-acid batteries. “The battery efficiency is 95%, compared to 70% for lead-acid batteries. Also, maintenance is minimal,” Tracy Shen continued. Electric motors require less maintenance than diesel trucks because fewer parts need to be repaired or replaced,” adds Tracy Shen. BSLBATT lithium-ion batteries last longer and require less maintenance, but like all advances in technology, they cost. Here is the cost. “The price is indeed quite high at the beginning, but we find that as the technology matures, the price drops quickly,” Tracy Shen said. “We should also remember that chemical reactions are complex and the automotive industry’s technologies are also falling in price rapidly due to their high volume. In a few years, lithium batteries will be more cost-effective than lead-acid batteries,” she added. Regarding lithium-ion batteries, residual value needs to be considered. A used battery by one player will be valuable to another player. To learn more, read:What’s the future for forklift lithium battery buyers? Driver’s dream Tracy Shen noted that the deal gets even better when you factor in fuel and battery life-cycle cost savings, adding another benefit of electric trucks. For those who drive them, that’s what’s most noticeable. “The KALMAR ECG80-6 electric truck with BSL lithium battery is quiet and does not produce a lot of noise. There is no vibration when the truck idles. No exhaust fumes. The truck is faster and accelerates better. Electric trucks are more efficient than diesel trucks over short distances,” she claimed. Heavy-duty electric forklifts equipped with BSLBATT lithium batteries are the future. We are here to shape it with our customers,” concludes Tracy Chen. BSLBATT lithium-ion forklift battery Lasts 2,500-4,000 cycles Battery efficiency is 97% Charging time: 1% per minute, fully charged in 100 minutes Charging on site No ventilation space required Requires minimal maintenance Opportunity charging can be applied for multi-shift operations Total ownership cost reduced
Precision, productivity, and progress: Intech’s inventory transformation journey with Kardex Remstar and ZOLLER
By integrating Kardex Shuttles with ZOLLER TMS Tool Management Solutions Software, Intech Athens has taken a monumental leap in streamlining inventory management processes, positioning them at the forefront of efficiency and precision in their industry. Through their dedication to delivering exceptional services and driving innovation, Intech has grown into a global leader in orthopedic contract manufacturing. One of nine global facilities, the Intech contract manufacturing facility in Athens, Alabama (formerly known as Turner Medical) specializes in the meticulous manufacturing of complex medical device instrumentation. As a distinguished medical device job shop, Intech Athens contracts for the production and manufacturing of medical device instruments essential for orthopedics, from complex hip and knee robotics devices to expandable spinal implants. Working at the intersection of medical science and engineering, Intech Athens plays a critical role in medical device innovation and production. Physicians, entrusted with the care of their patients, collaborate with industry-leading medical device Original Equipment Manufacturers (OEMs) such as Stryker and Medtronic. These medical professionals provide invaluable feedback—whether it’s developing a new surgical technique or a desire for a screw to fasten more swiftly, a tool to be more lightweight, or a design alteration to enhance accessibility during surgical procedures. The OEMs, armed with this feedback, turn to Intech Athens to make it happen. The team at Intech Athens uses their expertise and creativity to meticulously prototype the envisioned instrument for physicians to test on cadavers, ensuring utmost precision and safety. It’s amazing to watch an idea transform: from a prototype birthed within prototype dedicated cells (branded The Prototype Garage®) at Intech Athens, through the initial production stages, to its eventual market launch. The pinnacle of this journey is the patient whose quality of life has improved thanks to an implant or instrument crafted in this very facility—it’s an unparalleled reward. This is where the real essence of Intech’s work shines through, where every effort becomes profoundly meaningful. The Challenges of Rapid Growth To support this endeavor, Intech Athens boasts a 100,000-square-foot facility including a robust production area with over 70 CNC machines as well as engineering, quality assurance, regulatory compliance, and customer service – all supported by just over 220 employees (proudly known as Intechers). Intech’s commitment to innovation and investment in new technologies is paying off – Intech Athens has experienced an extraordinary 150% growth in the past decade. Amidst the rapid growth at Intech Athens, a new challenge became increasingly evident: the intricacies of inventory management. As the business expanded and the facility dove further into sophisticated manufacturing, inventory complexities multiplied. Transitioning from manual machining to CNC (Computer Numerical Control) machine manufacturing impacted the volume and variety of tools and supplies required. Each piece of CNC machinery had its own ecosystem: the cutting tool, its collar, the holder it sits in, the nut fastening it together and the retention knobs on the holder anchoring it into the machine. Beyond this, there is the work holding – including quick-change fixturing, vices, clamps, and an array of other components. Additionally, to ensure each product meets rigorous standards, very specific and elaborate gauging systems are essential. What appeared as a single manufactured component was, in reality, a culmination of 100+ manufacturing tools, gages, and supplies. Initially, Intech Athens used the traditional approach to manage inventory. Cabinets were grid-organized for less valuable smaller items while standard industrial shelving held larger items like fixtures and vices. Items were cataloged on clipboards and checked out manually, and it was expected that staff would conscientiously return them post-use. But as is often the challenge with manual systems, reliance on individual discipline and manual organization proved to be unreliable. Tools weren’t always returned to their designated spots, making it increasingly hard to locate specific items or determine their condition. Regular maintenance became an uphill battle. Recognizing the need for enhanced control, Intech Athens installed a vending machine system for cutting tools. These smart vending cabinets would vend specific tools based on several inputs, streamlining the process to a degree. However, this only addressed a fraction of the inventory. It wasn’t just about having the necessary tools—it was about knowing their exact location, quality, and readiness for use. “We were like any other job shop, we had the necessary items, but often didn’t know their location or condition. We knew we needed to do better,” said Joseph Forsyth, the Director of Advanced Manufacturing at Intech. Despite their growth and successes, Intech Athens found itself grappling with inventory control, a challenge they were determined to overcome. Revolutionizing Inventory Management To get control of their inventory, Intech had planned to leverage the ZOLLER Tool Management System software solution just as the Intech Toulon facility in France had done. But Intech Athens went a step further by integrating the ZOLLER TMS solution with high-density automated storage solution from Kardex Remstar. Stepping into the future of inventory management, they replaced their traditional racking systems and most of the cabinets with two state-of-the-art Vertical Lift Module Kardex Shuttles. Working in harmony with the ZOLLER TMS software, this complete solution not only provided better inventory control but also delivered significant space savings and increased manufacturing productivity. “From cutting tools to collars, vise jaws to sandpaper, and even dead blow hammers, we store them in the Kardex Shuttles. Through the ZOLLER TMS software, we’ve cataloged over 10,000 different part numbers. We now have unwavering clarity on our inventory—knowing precisely what we have and, more crucially, its exact location,” said Forsyth. Inventory Control Increases Speed to Market When it comes to medical device manufacturing, ‘speed to market’ is more than a catchphrase—it’s a determining factor of success. Particularly in prototyping, where swift turnarounds can be the difference between seizing an opportunity and missing out. For Intech Athens the reliability of their inventory control system is critical. “It’s not just about having the necessary items on hand. The real challenge is the speed at which we can access accurate data about the inventory. It’s about answering questions like, ‘Do we have the required tool for
Latest research report reveals Key Drive for ‘Accuracy’ Amongst Warehouse Operations
The importance of accuracy has doubled in two years; drive to adopt new technology in the warehouse to improve accuracy also increasing The latest report from StayLinked, independently conducted by VDC Research, shows that the focus on accuracy within warehouse operations has reached new heights. The drive for accuracy, to achieve the ‘perfect order rate’, has almost doubled since StayLinked’s 2022 survey. Provided with a list of ten different areas of improvement, accuracy was listed as the most important area by 15.1% of respondents, rising from 8.7%. “As market conditions continue to be volatile and unpredictable, this latest survey shows the importance of building accuracy into warehouse operations to drive resilience, flexibility and agility through accurate visibility of warehouse operations,” said Justin Griffith, StayLinked’s chief technology officer. The latest research from StayLinked, conducted by VDC Research, is published here: Making Supply Chain Resilience Work: Keeping Up with Ever-Demanding Warehouse Operations. The research of warehouse operations technology decision makers, across multiple industries including retail, manufacturing, transportation/logistics, retail, and wholesale organizations was conducted in 2023 and the report is being published now. “The 2022 survey was all about speed, with the focus being on-time shipments and getting orders out the door as quickly as possible,” continued Griffith. “That is still relevant now, but the focus on accuracy has leaped up.” Increased accuracy is not a pipe dream as emerging technologies can dramatically improve the accuracy of warehouse operations. Technologies also exist that can meet the survey’s other top improvement initiatives: continuing to ensure that goods are shipped quickly and helping to significantly improve the warehouse worker’s experience. However, to be adopted in the warehouse, these new technologies need to integrate with and ‘talk to’ the organizations’ warehouse management systems (WMS). This latest report highlights the link between the age of the underlying enterprise applications underpinning supply chain and warehouse operation and the ability to successfully deploy new technology. The report states: “There is a strong correlation between the age and flexibility of the underlying enterprise applications supporting logistics operations – be it WMS, ERP, WCS or others – and the ability for organizations to streamline logistics technology evaluation and integration. Maximum system flexibility is required to be able to integrate the planned, growth-defined future adjustments in warehousing and to control them in a coordinated manner.” The survey data showed that there has been an increased emphasis on the WMS – 61.1% of organizations were on the most current WMS or running just one or two years behind – a significant increase from 45% in 2022. This has seen a comparative increase in new technologies introduced into the warehouse. Warehouses that haven’t been able to move to the latest WMS will fear that they are in danger of permanently losing ground on their competitors. That fear is often combined with frustration at the impossible task ahead of them to replace the WMS. However, for those running an older WMS, it’s not true that a complex, risky, and expensive ‘rip and replace’ option is always required. “It’s like renovating your house. For most of us, we have to do it bit by bit, prioritizing different rooms as we go,” explained Griffith. “StayLinked can help warehouse operators similarly introduce new technologies. They don’t need to knock down the house – or rip out the WMS – in one go. They can simply adopt the new technology they need when they need it.” StayLinked’s enterprise-grade terminal emulation (TE) software SmartTE and its no-code technology adoption platform, Evolve, allow warehouse operators to modernize their existing WMS so that they can deploy a mixture of new technologies. One emerging technology will not rule them all, so it is crucial that multiple new technologies can be integrated into the warehouse operations’ workflows where they best fit and can deliver the most benefit, and at a pace that works for the warehouse operator. The research highlighted some of the emerging technologies that are most likely to be adopted by warehouses: Over 97% of warehouses plan to be using Locationing Systems and Predictive Analytics by 2027. Currently only in use by 20% of warehouses, nearly 85% of all warehouses plan to have deployed Person-to-Goods AMRs by 2027. Drones are the least popular of the emerging warehouse technologies. 36% of all surveyed said they had no plans to use drones at all. StayLinked can help warehouses quickly and easily integrate all of these new technologies into their existing warehouse management system to help them improve productivity, increase efficiencies, and most importantly, according to the research, improve accuracy. Download a copy of the report from StayLinked’s website: Making Supply Chain Resilience Work: Keeping Up with Ever-Demanding Warehouse Operations.
The hidden costs of industrial printing and how to reduce them
Identify hidden costs in two minutes with the total-cost-of-ownership-calculator How much do the printers you use on your production line cost? What we mean is, how much do they cost? As the pressure increases on producers and packagers to make their production lines more efficient, we are often asked about how our customers can reduce their printing costs. And the answer we give often surprises them. Here are six ways that your printers cost money and how to reduce your total cost. Not only that – you will also get access to our new TCO calculator, which will give you an actual figure personalized to you and your business. So where is all that money going? 1. Downtime This is the cost that is most often overlooked when talking about coding & marking. Downtime can be created by poor print quality as well as by poor printer performance. Some conventional printers need cleaning between pauses in production. So, the production line sits idle while someone takes the printer through the cleaning cycle. Some printers can take up to 20 minutes to stabilize before they are ready to print again. This delay costs money: according to Senseye’s True Cost of Downtime Report, the cost of a lost hour ranges from USD 39,000 in the FMCG sector to more than USD 2 million in the automotive sector. With LEIBINGER, this is not a cost you need to worry about. The LEIBINGER printer technology keeps unused ink in a 100% airtight system. It doesn’t dry out or clog, production schedules are not held up for cleaning, and no precious production time and money is wasted. High-quality printing results are guaranteed at any time. 2. Maintenance It’s important to keep machines serviced and in good working order, and this can be a significant part of the overall cost unless you have a LEIBINGER IQJET. The IQJET is maintenance-free for five years. This is possible because we use durable, high-quality components and a unique product design that minimizes ‘wear and tear’ (e.g. no need for a continuously running feed pump). And it removes the maintenance cost altogether. In contrast many of the other prominent printing solution providers today seem to lack a crucial focus on minimizing parts and maintenance requirements, as their approach revolves around the wholesale replacement of entire ink core modules, which means the entire hydraulic system, at predetermined time intervals such as annually or biennially. Typically, this process is governed by timeout chips, leading to automatic printer shutdowns when these intervals expire. Consequently, this enforced printer downtime results in production halts for manufacturers. This approach not only lacks sustainability but also incurs exorbitant costs. We are not merely referring to the substantial expenses incurred in replacing ink core modules, which are up to USD 1.500 per year; Downtime costs, in terms of lost production, are equally significant. Therefore, the query regarding maintenance and spare parts policies should be one of the primary questions to ask your coding and printing solutions provider, as it can constitute a significant long-term cost factor. 3. Labor Given the current labor shortage, it is particularly important to consider the time cost of people. How long do operators spend setting up or cleaning printers? Or re-programming them between jobs? What is the expected timeframe for commissioning and installation at the facility? Printers that are easy to install, manage, configure, and with remote control options. For example, staff don’t have to walk miles around the plant to operate them will cost less in the long run. Such features are included in LEIBINGER printers. The Plug & Print performance of IQJET is unparalleled in the global market. The drag-and-drop interface and the simplest print job creation process are not only effortless but also highly intuitive, and no extensive training of employees is required. 4. The purchase price The most obvious cost of printing is the upfront cost of equipment, although this is typically less than 30% of the total costs. As with everything, a high-quality, reliable brand will cost more than a cheaper one. And of course, printers cost more if they go faster or provide more features – so the best way to economize is to ensure you don’t pay for features or speeds that you don’t need. In the long term, the best bet is a reputable supplier with a wide range so you can find a price point that suits you. 5. Consumables Reduce the amount of ink and solvent you use, and reduce your costs.Not all printers perform equally. LEIBINGERs latest printers have one of the lowest consumption ratings on the market, 2.7 ml per hour of solvent for MEK inks (competing products typically consume between 6 and 10 ml per hour), and we make sure that ink cartridges are emptied down to the last drop and do not require separate disposal (unlike many conventional CIJ systems). So, you pay less for your consumables. 6. Power Energy prices remain high, so the power required to run your printers is an important factor. Not only does it cost money, but it also contributes to your organization’s carbon footprint. Choose equipment with a low wattage rating, such as our new IQJET: drawing only 36W it costs less than any other printer to run. Show me the money! While it is useful to know the different ways that your printers cost money, you need to see the numbers. You need to know exactly how much you’re paying and how much could you save. And with our online Total Cost of Ownership Calculator, you can have those numbers in about two minutes. Check out the Total Cost of Ownership Calculator now. About the Author: About Paul Leibinger GmbH & Co. KG (LEIBINGER) LEIBINGER is a globally operating specialist in coding & marking systems with headquarters in Tuttlingen, Baden-Württemberg (Germany). The third-generation family-run company, founded in 1948, develops and produces industrial inkjet printers as well as inks for various applications – with a workforce of close to 300. Innovative technologies and an
IDEC 7” combined PLC+HMI increases display size and I/O options
A large 7” vivid multi-touch display, with an integrated controller and expandable I/O, enables the new FT2J Series PLC+HMI to handle more applications than ever before. IDEC Corporation has expanded its SmartAXIS touch family with the new FT2J Series combined PLC+HMI. A compact all-in-one form factor combines built-in full-function controller features and functions, both onboard and expandable I/O, and an advanced technology 7” touchscreen display, providing many advantages for a wide variety of industries. Compact, simple, and streamlined An all-in-one PLC+HMI is compact and consumes far less panel space than separate units. Because the PLC and HMI are internally connected, require only one power supply, and share the same network connection, installation is simplified. The FT2J is ready to use and communicate right out of the box, and end users perform configuration with an intuitive and easy-to-use integrated development environment for both PLC and HMI functions, cutting configuration and programming time. Powerful PLC features The integrated PLC and HMI each have their own dedicated CPU and user memory for optimized scan time performance, and they communicate natively with each other. Built-in I/O includes 14 points of DC discrete inputs (5 of them configurable as high-speed counters), and 4 points of analog inputs (configurable as 0-10VDC or 4-20mA). A relay version provides 8 points of relay outputs, while transistor versions provide 6 points sinking or 6 points sourcing of discrete outputs (4 of them configurable as pulse outputs) and 2 points of 0-10VDC or 4-20mA analog outputs. The FT2J supports up to two expansion cartridges of discrete or analog I/O, with several options offered including a 2-point RTD/thermocouple analog input version. All analog inputs and outputs are 12-bit resolution. Industrial-grade HMI design The HMI’s projected capacitive touch panel (PCAP) advanced technology—similar to what is used for smartphones and tablets—saves space and improves performance. Besides being water- and scratch-resistant, PCAP is responsive and provides a high tolerance to resist false signals when dirt or water droplets are present on the face of the HMI. Fewer layers and better light transmission ratings mean less backlight power is needed, and the display provides an industry-leading 500 cd/m² brightness level and 50,000-hour backlight life. A small bezel provides the greatest possible display area compared with the installation footprint, and the entire package requires only a shallow mounting depth clearance. In addition to being multi-touch, users can interact with the touch HMI while using thin gloves. Durable performance The glass-top design is wear-resistant and delivers a long life, even in harsh environments. A battery-free design using a hyper-capacitor, and a long 50,000-hour rated backlight life, make these units low maintenance. Ratings for extreme temperatures from -20 to 55˚C, IP66 and IP67 for wash-down areas, IP66F and IP67F for oil resistance, UL60101, UL Type 4X/12/13, and Class I Div 2 mean the FT2J PLC+HMI can be used in a wide range of applications and locations. Flexible configuration All PLC and HMI configuration is accessed through IDEC’s standard WindOI-NV4 software, which is easy-to-use and intuitive, with a drag-and-drop interface and extensive image library. Projects can automatically be converted from one HMI size to another within seconds. Script programming, PIDD loop control, multilingual capabilities, security, trend charts, data logs, alarm logs, and other functions and features are supported for both the HMI and the PLC. Connectivity Two USB-A ports support flash drives for data logging, recipes, and program transfer—along with dongles for speakers, Wi-Fi, and Bluetooth. The embedded Ethernet port provides users with easy access for remote maintenance and communication as well as Modbus TCP protocols and other intelligent devices. The built-in RS232C and RS422/485 serial communication ports support Modbus RTU and also allow the FT2J to communicate to other serial devices like barcode readers or temperature controllers. Communications and IIoT Many communication options are available for users to create automation and IIoT solutions incorporating multiple industrial protocols, the FTP protocol, remote monitoring and control, email/text messaging, iOS and Android apps, and custom web pages.
Analysis of the Top Nine misunderstandings about forklift lithium-ion batteries
Interest in and use of lithium-ion batteries in industrial trucks is growing. There are many advantages to this revolutionary technology, most notably its fast charging and ability to charge “on the go” rather than “charge to full” all at once. However, there remains widespread confusion and misunderstanding about battery technology and its suitability for material handling applications. Visit our Forklift Lithium Battery website or read on for what BSL Battery – Industrial technical experts have to say about some misconceptions. 1. We do a lot of heavy lifting that electric machines can’t handle With modern battery-operated equipment, lifting capacity is not an issue. If the capacity plate rating is the same as the equivalent internal combustion engine (ICE) model, the ability to lift heavier loads is also the same. For example, Hyster®’s updated J2.5-3.0XNL trucks are designed to match hydrostatic IC trucks. Also, remember that while lifting uses a lot of energy, electric forklifts are more energy efficient than IC forklifts, so the only real potential drawback is the machine’s ability to store and use that energy. This means the end user must consider whether there are sufficient opportunities to recharge the battery throughout the day. This video provides an in-depth look at how lithium-ion technology works and how Hyster® can replace multiple lead-acid batteries depending on truck power requirements while increasing productivity! 2. You can get all the benefits by replacing your lead-acid batteries with lithium-ion batteries Of course, aftermarket lithium-ion batteries are a huge improvement over lead-acid batteries, but to enjoy the real benefits, you should consider a forklift factory-approved OEM lithium-ion battery manufacturer, which has inherent advantages. For example, the integrated battery has CANbus connectivity, which means the truck’s factory BDI still works accurately. The OEM technician can connect to the battery and diagnose any issues through the truck software, eliminating the need to call a 3rd party provider. In addition, BSL Battery is a major lithium battery supplier in China. It serves Toyota Material Handling, Combilift Forklift, Clark Forklift, Xilin Forklift and Raniero Forklift. When considering a swap solution (lead-acid batteries replacing equivalent lithium-ion batteries), users must determine whether their application allows sufficient time to charge the batteries. They also need to consider additional energy infrastructure costs, such as cables and sockets capable of handling higher power consumption. In addition, they need to install new power points closer to work areas or break rooms to avoid unnecessary trips to existing lead-acid charging room distances. 3. Lithium-ion batteries are very expensive It’s imperative to think about long-term costs. Although lithium-ion batteries have a higher initial purchase price than lead-acid batteries, their cost per cycle is lower due to their longer lifespan, making them the most cost-effective solution in the long run. BSLBATT’s lithium-ion batteries, in particular, have extremely low internal resistance and the most efficient technology, which means less grid energy is wasted and saves 30% (charging and CO2 emissions) compared to lead-acid batteries. Therefore, in the long run, with the decline of lithium carbonate, now comparing the prices of lithium-ion batteries and lead-acid batteries, purchasing a lithium battery with the same capacity only costs 1.5 times that of a lead-acid battery. Lithium batteries are cheaper in the long run. 4. We need to replace our entire lead-acid fleet with lithium-ion machines Of course, it often makes sense to replace the entire fleet so that operators don’t have to switch between different charging regimes and operating procedures. It also makes sense for the aging fleet, which has decided to retire all existing machines and “start over.” Replacement is also recommended when a business has an incentive to replace. This could be a commitment to reduce overall CO2 emissions or a desire to eliminate hazardous battery replacement or reduce ongoing maintenance requirements. However, if the utilization of certain trucks is not sufficient to warrant lithium-ion batteries, a mixed fleet is possible and we have helped many customers with phased rollouts. If you operate a mixed fleet, you need to know that lead-acid and lithium-ion batteries often require different chargers, so charging areas may need to be marked and instructions provided to staff. 5. Our power supply must be upgraded Yes, lithium-ion battery chargers have higher output, which means they require higher input current than lead-acid chargers. However, BSL Battery – Industrial offers a variety of battery/charger combinations based on utilization, application intensity, and available charging window. At the same time, to reduce customers’ charger investment, we have communicated with the world-renowned SPE, Fronius, and Delta-Q, which means that customers do not need to purchase additional chargers when switching to BSLBATT lithium batteries using chargers from these three brands. Charger! 6. Our drivers must be retrained and change their work habits Agreed, retraining is required as standard AS2359:2 practice states that each user should have a safe work systems policy in place, including supervisory practices, on-the-job training, and ongoing regularly updated training. Therefore, users must maintain records of ongoing training. The good news is that lithium-ion batteries are easy to use The battery management system communicates with the charger to prevent overcharging. It manages power delivery to prevent excessive discharge. It does not require charging or watering to work properly. The operator must simply know how to plug it into the charger when not used. Our clients found that their work habits needed to change, but for the better. Battery maintenance tasks are virtually eliminated, as are hazardous battery replacement and battery damage due to battery misuse. Unlike lead-acid batteries, lithium-ion batteries thrive on opportunistic charging, meaning operators can charge the forklift during breaks. The charging process will be faster and easier since there is no longer a need to open the hood to connect the charger to the truck. 7. Lithium-ion batteries are not as stable as lead-acid batteries and pose safety threats This is a common myth, but lithium-ion batteries are safer than traditional lead-acid batteries. Although the energy density is higher than that of lead-acid batteries, BSLBATT lithium-ion batteries have multi-level safety systems such as cells, modules, and casings, as well as a battery management system (BMS) with comprehensive protection functions.
Maximizing Warehouse Space: Unleashing potential with Next Level’s Mezzanine Solutions
Optimizing warehouse space is a critical endeavor for businesses looking to enhance efficiency and reduce operational costs. One innovative solution gaining popularity is the use of mezzanine systems, and Next Level stands out as a provider that prioritizes strength, stability, and cost-effectiveness. In this article, we explore how Next Level’s mezzanine systems can help you maximize your warehouse space with their robust features and thoughtful design. Section 1: The Strength Advantage Next Level distinguishes itself through an unwavering commitment to providing mezzanine systems with unparalleled strength. The foundation of this strength lies in the meticulous selection of materials and construction techniques employed by Next Level, ensuring that their mezzanine systems offer robust support for diverse loads while maintaining long-term durability. Next Level’s emphasis on utilizing the strongest possible connections within their mezzanine systems speaks directly to the reliability and safety of these structures. Heavy-duty columns, carefully chosen for their load-bearing capabilities, are strategically incorporated to create a solid framework that stands up to the challenges of a bustling warehouse environment. This robust construction not only allows for the efficient use of vertical space but also instills confidence in businesses looking to optimize their storage and operational capacities. Moreover, the strength advantage provided by Next Level’s mezzanine systems contributes to the overall stability of the structure. This is especially crucial in warehouses dealing with heavy inventory or machinery. The mezzanine’s ability to withstand substantial loads without compromising stability ensures a secure and dependable platform for storage or operational needs. Beyond the immediate benefits, the strength advantage becomes a long-term asset for businesses, minimizing concerns related to structural integrity and reducing the likelihood of costly repairs or replacements. By investing in Next Level’s mezzanine systems, businesses can be confident that their warehouse space is fortified with a foundation designed to withstand the rigors of daily operations while providing a robust and enduring solution for maximizing storage capacity. Section 2: Stability without Bracing One of the distinctive features that sets Next Level’s mezzanine systems apart is their innovative design that eliminates the need for knee bracing or diagonal bracing. This design philosophy goes beyond mere aesthetics, presenting tangible benefits in terms of both installation simplicity and the creation of a versatile and unencumbered workspace beneath the mezzanine. Traditional mezzanine structures often require diagonal bracing or knee bracing to enhance stability, which can, in turn, limit the open space below. Next Level challenges this norm by engineering mezzanine systems that boast inherent stability without the need for additional bracing elements. This not only simplifies the installation process but also opens up possibilities for businesses seeking a more flexible and streamlined floor plan. The absence of knee bracing or diagonal bracing beneath the mezzanine creates a spacious and obstruction-free area that businesses can utilize for a variety of purposes. Whether it’s organizing inventory, setting up workstations, or accommodating machinery, the unobstructed space fosters an environment where operational efficiency and adaptability thrive. Furthermore, this design choice contributes to a cleaner and more visually appealing warehouse layout. The absence of additional bracing elements not only enhances the overall aesthetics but also facilitates easier navigation and movement within the warehouse. Businesses can, therefore, design their floor space with greater freedom, optimizing the layout to suit specific operational needs without the constraints imposed by traditional bracing requirements. In summary, Next Level’s commitment to stability without bracing not only simplifies the installation process but also transforms the space beneath the mezzanine into a versatile canvas for businesses to optimize their workflow and spatial efficiency. It’s a testament to Next Level’s forward-thinking approach to mezzanine design, providing a solution that not only meets structural requirements but also enhances the overall functionality and aesthetic appeal of the warehouse environment. Section 3: Zinc Coating for Durability Next Level takes a proactive approach to ensuring the longevity and durability of their mezzanine systems by offering zinc-coated beams, struts, and joists as a standard feature from the factory, without incurring any additional cost. This meticulous coating process involves applying a layer of zinc to the structural components, creating a protective barrier against corrosion, rust, and environmental wear and tear. The zinc coating not only serves as a shield against the harsh conditions commonly found in industrial environments but also enhances the overall lifespan of the mezzanine system. This protective layer acts as a corrosion-resistant barrier, preventing degradation over time and reducing the need for frequent maintenance. As a result, businesses can rely on Next Level’s mezzanine systems for sustained performance, minimizing the risk of structural deterioration that might compromise the safety and functionality of the warehouse space. In addition to its protective qualities, the zinc coating contributes to the aesthetic appeal of the mezzanine components. The clean and polished appearance not only reflects a commitment to quality but also adds a professional touch to the overall warehouse environment. By incorporating zinc-coated elements into their mezzanine systems, Next Level ensures that businesses not only maximize their storage capacity but also invest in a solution that stands the test of time and looks great doing it. Section 4: Cost-Effective Solutions Next Level’s dedication to providing zinc-coated components without additional charges extends beyond durability; it translates into a cost-effective solution for businesses seeking to expand their warehouse space. The decision to include zinc coating as a standard feature without extra cost reflects Next Level’s commitment to delivering value and reducing the total cost of ownership over the lifespan of the mezzanine system. By opting for Next Level’s mezzanine systems, businesses not only benefit from the durability and corrosion resistance of zinc-coated components but also make a strategic investment in long-term cost savings. The reduced need for maintenance and potential replacements due to corrosion leads to lower operational costs and a higher return on investment over time. In summary, Next Level’s combination of zinc coating for durability and a commitment to cost-effective solutions ensures that businesses not only maximize their warehouse space but do so with a keen eye on durability, maintenance costs, and long-term financial benefits. It’s
Thomson video explores shift toward electrification of applications using linear actuators
Thomson Industries, Inc, a manufacturer of linear motion control solutions, has released a video: ‘Clean and Simple: The Electrification of Applications with Linear Actuators,‘ which highlights the growing trend towards electric actuators and the advantages they bring over traditional technologies such as hydraulic, pneumatic and even manual actuation. For decades, hydraulic and pneumatic systems have been the preferred choice for heavy-duty applications. However, these systems pose challenges, including complexity, noise, high energy consumption, safety concerns, and adverse environmental impact. Electric actuators are now changing the game. This video explores the shift toward electric actuators, highlighting the increased load-handling capabilities that put them on par with hydraulic systems, as well as advanced controls and diagnostics that enable seamless communication with other machines in the network. The video also touches on numerous advantages of electric over traditional systems, including compact design, simplified wiring, and being entirely fluid-free, ensuring zero leaks, and minimal energy consumption and maintenance. “Electrification isn’t just a technological leap; it’s a profound transformation in how we approach motion control. It’s about harnessing efficiency, ensuring reliability, and securing a sustainable future,” said Travis Gilmer, Product Line Manager – Linear Actuators at Thomson. A prime example of how far electrification has come is the new Thomson Electrak® XD actuator, which can handle larger loads, longer strokes, and higher travel speeds, all with increased durability. Additionally, the XD goes toe-to-toe with hydraulics in shock load handling, making this unit versatile for various applications. Thomson’s commitment to innovation is driving the trend toward electrification in motion control applications. Their electric actuators are the embodiment of advanced controllability and safety and provide unparalleled durability. To explore these innovations further, click on the video link here – Clean and Simple: The Electrification of Applications with Linear Actuators | Thomson (thomsonlinear.com).