Enhancing Goods-to-Person Operations with Pacline Overhead Conveyors

Goods-to-Person (GTP) is an advanced warehouse automation system that enhances efficiency by moving products to stationary workers. In GTP operations, automated technologies such as unit sorters, zone routing, cASRS, and AMRs deliver items to workers at fixed picking/packing stations, minimizing travel time and boosting productivity. PACLINE’s overhead conveyor systems complement these setups by ensuring a consistent supply of empty cartons or totes to packing and sorting areas, helping distribution centers maximize workflow efficiency and throughput. By reducing manual handling and maintaining an organized, clutter-free workspace, PACLINE conveyors enhance the flow of operations while saving valuable floor space.

Unit Sorters

Unit sorters are similar to large, automated put walls, ideal for moderately high SKU populations and fast-paced operations. These systems excel when high-speed sortation is required for products such as clothing or shoes that are not easily damaged. Goods are induced into unit sorters by emptying donor totes or cartons, typically containing a single SKU. The sorter then directs items into individual orders using chute-based routing technologies like tilt-tray or bomb-bay systems. Once an order is filled, associates transfer the contents from the storage pod to a shipping carton, close it, and push it onto a takeaway MDR conveyor underneath the chutes.

Pacline monorails are ideally suited to deliver shipping cartons to associates at an ergonomic height and provide a reliable supply of empty cartons in moderately high-SKU environments where unit sorters handle high-speed sortation. Configurations can be routed above chutes or behind operators, supporting rates of 10 to 20 cartons per minute depending on the size and style of carriers utilized. This reliable flow minimizes delays, keeping the system running at peak efficiency.

Zone Routing Systems

Pick-and-Pass Motor-Driven Live Roller (MDR) technology is used in situations with moderate SKU populations and order velocity. Pick-and-Pass conveyors are also ideal for fragile goods that are ill-suited for high-speed sortation, such as beauty products and high-end luxury items. Full bins containing a single SKU are brought to order picking associates, who will pick the count of that SKU needed for the current order. These are placed into shipping cartons on a tilted shelf near the associates. Once an order is filled, the associate will push the carton onto a takeaway MDR routed behind the tilted shelf.

Pacline’s overhead monorail conveyors deliver empty cartons directly above the shelves or Pick-and-Pass conveyors, ensuring that associates have a steady supply of shipping cartons. The overhead configuration can fit neatly into available overhead space and work in conjunction with the Zone Routing technology.

Cubic Automated Storage and Retrieval (cASRS)

Cubic Automated Storage and Retrieval Systems (cASRS) such as AutoStore™ can be utilized in dense, highly automated order fulfillment environments with an extremely high SKU population and order velocity. Typically, cASRS systems are also ideal for fragile and high-value goods since manual handling of such items can increase the probability of damage. The cASRS system retrieves bins full of single SKUs from throughout its dense storage system and rapidly brings them to the picking/packing Associates, each situated at a pod.

The PAC-LINE™ monorail is typically routed behind the Associates, parallel to the cASRS pods, to deliver empty cartons to operators handling high-value or fragile goods. The ability to navigate elevation changes and to create egress paths for Associates makes Pacline overhead systems a superior choice over roller conveyors.

Autonomous Mobile Robots (AMRs)

For order fulfillment operations with a high SKU population but moderate or low order velocity, using a Person-to-Goods method can be challenging as it results in wasted Associate movement (or deadheading). Autonomous Mobile Robots (AMRs) improve efficiency by bringing items directly to stationary workers. AMRs transport bins filled with single SKUs to workers, who pick the required items and place them into shipping cartons.

Pacline’s overhead monorails complement AMRs by ensuring a steady supply of empty cartons or totes at ergonomic heights, allowing workers to focus on picking without interruptions and reducing unnecessary movement.

Why Choose Pacline Conveyors for Goods-to-Person Fulfillment?

Pacline overhead (monorail) conveyors are designed for adaptability, scalability, and efficiency, making them the perfect complement to GTP operations.

Contact Pacline today to learn how our conveyor systems can support and enhance your goods-to-person operations. Let our team design a solution tailored to your needs, maximizing efficiency and productivity in order fulfillment processes.