LVP Automation logo

Logistics & E-commerce Conveyors

Distribution centres live or die on flow. Product has to reach a picker, a packer and a despatch lane in the right order, and the empties have to get back without blocking the aisle they came down. LVP Automation builds conveyor and sortation systems for logistics and e-commerce operations, generally into buildings that are already full and already running.

The two systems below are a book distribution line for Easons Wholesalers and a two-tier tote handling system for a distribution centre. If you are laying out or reworking a facility, see conveyor system design; where throughput or a merge point is the uncertainty, a simulation model can answer it before anything is bought. For equipment, see roller conveyors and warehouse technology and storage. We are based in Finglas, Dublin 11 and work with operators across Ireland.

On this page
Book Distribution Line, Easons Wholesalers
Two-Tier Tote Handling and Sortation
Common Questions

Book Distribution Line, Easons Wholesalers

Easons Wholesalers, a major book distributor in Ireland, were running order taking, picking, packing and despatch on manual systems that the daily order volume had outgrown. LVP Automation built the conveyor system to carry that work instead.

The line uses line shaft powered roller, which suits boxes of books because it gives close control over where a box is and when it moves — and that control is what makes automated sorting and packing reliable rather than approximate. The system was integrated with the sorting and packing machinery already in the building rather than replacing it, and laid out to fit the space the distribution centre actually had.

What the Easons Line Delivers

  • Line Shaft Powered Roller: This conveyor type is ideal for transporting boxes of books, offering exceptional control over product movement, which is essential in a busy distribution environment.
  • Increased Accuracy: By automating the sorting and packing processes, the new system significantly improved order accuracy, minimising the risk of errors that could impact customer satisfaction.
  • Faster Processing: The streamlined operations led to quicker processing times, enabling Easons to handle a higher volume of orders efficiently without sacrificing quality.
  • Custom Integration: LVP tailored the conveyor system to seamlessly integrate with existing sorting and packing machinery, enhancing overall production without requiring major modifications to the current setup.
  • Efficient Space Utilisation: The design maximised the use of available space within the distribution centre, which is critical for maintaining smooth operations and meeting high demand.
  • Enhanced Throughput: The new system increased throughput significantly, ensuring that boxes were correctly packed and shipped to their intended destinations in a timely manner.

Two-Tier Tote Handling and Sortation

A distribution centre needed to solve sortation and, just as importantly, the return of empty totes. Full totes going one way and empties coming back is where most pick faces congest, and it usually shows up as operators waiting or walking rather than picking.

We built a two-tier gravity tote system on a custom aluminium frame. Full totes run on one tier and empties return to the picking area on the other, so the two flows never compete for the same lane. Ball table units give 360-degree movement at the sortation points, so a tote can be pushed in any direction by hand rather than lifted, and each lane holds up to six totes. The workstations were laid out around what operators actually have to reach.

What the Tote System Delivers

  • Gravity Tote System: This innovative solution efficiently manages both full and empty totes, enhancing overall operational efficiency and ensuring a smooth workflow.
  • Custom Aluminium Frame: Built for durability and strength, the frame supports various operational demands, making it suitable for heavy-duty use in a busy distribution environment.
  • 360-Degree Sortation: The inclusion of ball table units enabled comprehensive sortation capabilities, facilitating smooth tote movement in all directions, which is essential for efficient handling.
  • Space Optimisation: The two-tier design maximised available space, allowing empty totes to return to the picking area without causing congestion, thereby improving workflow.
  • High Throughput: The system was designed to manage up to 6 totes per lane, significantly boosting productivity and enabling quick order processing.
  • Safe Operation Features: Gravity brake rollers were incorporated to prevent runaway situations, ensuring a safe working environment for operators and reducing the risk of accidents.

Common Questions

What is usually the hardest part of a tote system? Getting the empties back. Most designs concentrate on moving full totes out to the pick face and treat the return as an afterthought, which is where congestion starts. The two-tier system above exists specifically so the two flows never share a lane.

Can a new system work with our existing sorting and packing machinery? Yes, and it is usually the cheaper route. The Easons line was integrated with equipment already in the building rather than replacing it.

Why line shaft powered roller for cartons? Because it gives control over exactly where a carton is and when it moves. On a line feeding automated sorting and packing, knowing the position of each box is what makes the automation dependable.

How many totes can a lane hold? Six on the system above. The right figure comes from your pick rate and how long a tote sits before it is taken, so it is worth working out rather than assuming.

Can we test the throughput before committing to a layout? Yes, and on a distribution centre it is often worth it. A simulation model will show where product queues and which section sets the ceiling, before any steel is ordered.

Our building is already full. Does that rule it out? Not usually, but it does drive the design. Both systems above were built to fit the space available rather than an ideal layout, which is the normal starting point rather than the exception.

Where do you cover? We are based in Finglas, Dublin 11 and work with customers across Ireland.

Let's Connect

Have a question about our conveyor systems or need a tailored automation solution for your business? Our team at LVP Automation is here to help. Fill out the form below with your details, and we’ll get back to you as soon as possible. Whether you need a quote, technical support, or more information on our products, we’re ready to assist.

SCHEDULE A CONSULTATION

Need more help?

Sales

sales@conveyors.ie

Free Consultation

+353 1 864 3838

Our Services