Enhancing Person-to-Goods Operations with Pacline Overhead Conveyors

In the ever-evolving landscape of eCommerce and retail, optimized order fulfillment systems are essential. At Pacline Conveyors, we understand the unique challenges of person-to-goods operations. Whether you’re managing a multi-level Pick Module or a single-level indexing break-pack loop, our overhead conveyor systems are designed to improve workflow, increase productivity, and reduce operational costs. 

Pick Modules: Driving Efficiency in Order Fulfillment

Pick Modules—whether single or multi-level—are the backbone of many distribution centers handling low-to-moderate SKU populations and moderate order velocities. These operations require precise, reliable, and fast empty carton delivery systems to ensure associates can focus on picking. Pacline’s overhead monorail conveyors are an ideal solution for these environments, especially when floor space is limited. 

Pacline’s monorail carton induction system delivers empty cartons to workers at optimal heights, reducing strain and increasing efficiency. This setup allows associates to remain focused on fulfilling orders rather than handling empty boxes or navigating through cluttered workspaces. 

The PAC-LINE™ monorail system excels in high-throughput operations, delivering up to 36 small cartons per minute for eCommerce orders and 10 to 20 cartons per minute for larger retail replenishment cartons. The system’s design ensures that cartons are delivered above the takeaway conveyor and at ergonomic heights, keeping the workspace clear and streamlined. 

Break-Pack Loops: A Versatile and Scalable Solution

Break-pack loops provide a cost-effective solution for operations with lower SKU counts but higher order velocity than cart-picking. A break-pack loop is typically a single-level picking system that utilizes a circuit-shaped roller (MDR) conveyor with an indexing operation. Associates pick items into cartons placed on the conveyor, and once the order is complete, the carton is transferred to a parallel takeaway conveyor for further processing. 

Pacline offers two key solutions for break-pack loops, each tailored to meet the demands of fast-paced order fulfillment environments: 

1. The Pac-Max™ Conveyor System: The Pac-Max™ conveyor provides a cost-efficient alternative to traditional roller conveyors, especially when space is limited. With its heavy-duty design, the Pac-Max™ operates in a floor-level configuration, utilizing tray carriers to transport cartons weighing up to 60 lbs. safely. Unlike traditional roller conveyors, the Pac-Max™ allows for compact elevation changes and tighter turns, enabling semi-filled cartons to move seamlessly between different levels of your facility. This system also keeps cartons separated at fixed intervals, reducing the risk of jams and ensuring a smooth flow of goods. The Pac-Max™ is an ideal solution for order fulfillment operations that require flexibility, as it can be easily expanded or modified to accommodate changes in demand or layout.

2. Overhead Monorail Solution: The overhead monorail efficiently manages empty carton delivery in break-pack environments. Empty cartons are delivered at ergonomic heights above the break-pack conveyor (whether a roller conveyor or a Pac-Max monorail), ensuring associates can easily access them without strain. This system also offers the flexibility to handle corrugated trash removal—as empty vendor boxes are processed; they can be quickly and easily removed from the area. Pacline’s monorail solution allows for both manual removal of trash cartons or fully automated removal using sophisticated trash management systems. 

Why Pacline Conveyors? 

At Pacline, we understand that every distribution center is different, and we are committed to providing customized conveyor solutions that meet your specific needs. Whether you’re looking to improve the efficiency of your Pick Modules or implement a more adaptable break-pack loop, our conveyor systems offer reliability, flexibility, and performance to keep your operations running smoothly. 

Contact Pacline today to learn how our conveyor solutions can transform your person-to-goods operations and take your fulfillment processes to the next level.