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Make Your Old Sortation System Run Like New
January 27, 2022
Automated sortation systems are more important than ever before when it comes to satisfying the e-commerce expectations of vendors and consumers alike. As with any system that runs continuously, it’s not unusual to see a gradual decline in performance after many years of service. But that doesn’t mean you have to choose between expensive, inefficient workarounds or replacing the entire system.
In fact, many sortation systems can effectively be restored to “like new” condition — for a fraction of the cost of installing all-new equipment — simply by refreshing key wearable components. Depending on the age and model of your system, you may even benefit from modern improvements and upgrades that:
- Boost product handling
- Reduce vibration
- Increase component service life
- Eliminate catchpoints
- Minimize debris entry
- Smooth transitions for product exiting the sorter
- Enhance reliability
- Expand the variety of product and packaging types your system can handle
- Minimize gaps, reducing fall-through
- Reduce the complexity of your system
When Is It Time to Refresh?
If you’re experiencing one or more of the following issues, there’s a good chance your sortation system is no longer running at peak performance:
- Frequent unplanned downtime
- Increased energy consumption
- Poor conveying surface performance (this often causes packages to bounce, jam or become damaged)
- Inaccurate diverting
- Higher recirculation rates
- Excessive noise
If any of these conditions sound familiar, resist the urge to “just live with it”. Complications like these aren’t merely nuisances; they’re warning signs that an aging system is slowing your throughput and creating unnecessary expenses, such as extra maintenance and repairs, avoidable product damage, and more. And performance losses aren’t the only concern. A sorter’s gradual decline may even be creating an unsafe environment for your workers.
Fortunately, all of these challenges can potentially be eliminated in a matter of days.
Restore Performance With a Not-So-Extreme Makeover
Even if your system is more than 10, 15 or 20 years old, much of its structure may be sound enough to provide many additional years of service. In fact, most sortation system overhauls primarily involve replacing wearable components like chains, slats, guides, switch assemblies, and so on.
Sortation rebuild experts from Honeywell Intelligrated can assess existing systems quickly to identify issues that are impacting performance, components that need replacements, and opportunities for cost-effective upgrades. These improvements can be implemented in a matter of days, bringing your system back up to peak efficiency with less downtime than you’d need for a new install — and at a fraction of the cost.
Once completed, this high-value restoration work can deliver immediate benefits to your operation, including:
- Increased throughput
- Improved diverter accuracy
- Less unplanned downtime
- Enhanced energy efficiency
To learn more, please read the application brief, Rebuild Your Sortation System to Like-New Condition, which includes more details about common replacements and upgrades. You can also contact us to determine if your system is a good candidate for a rebuild.
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