Pacline Conveyors recently had the privilege of attending a special Sponsor Appreciation Event hosted by FIRST Robotics Team 1325 – Inverse Paradox. Inverse Paradox comprises of over 30 high school students and mentors who work together each year to design and build industrial-size robots to compete against other FRC teams. The evening was a celebration of innovation, collaboration and Pacline was proud to play a central role in empowering the next generation of engineers and technology leaders.

In addition to sponsoring the team, Pacline has opened its facility to serve as a dedicated workspace for the robotics team. During the event, Pacline was formally recognized by the robotics team for its ongoing support. The team expressed heartfelt gratitude for our sponsorship and for allowing them to innovate and build their competitive robots within our facility. Seeing their success and enthusiasm reminds us why giving back to our community is so important.

Moments like this reinforce our commitment to making a positive impact beyond business by helping shape the future of engineering and automation.

TL;DR

Overhead monorail carton induction optimizes fulfillment operations by using overhead space, reducing maintenance and labor costs, and preserving MDR capacity for product movement. Compared to MDR-based or manual case erection methods, monorail systems offer higher throughput, lower total cost of ownership, and a more ergonomic, efficient picking environment. Download the Business Case PDF to compare overhead monorail, MDR, and manual carton induction across all major criteria.

When evaluating methods for delivering empty cartons to picking areas, distribution and fulfillment centers face a choice between three common solutions: overhead monorail conveyors, MDR (motorized driven roller) conveyors, and manual case erection. While all aim to keep pickers supplied with corrugate, they differ significantly in cost, efficiency, space requirements, and operational impact. 

Why Choose an Overhead Monorail for Carton Induction? 

Overhead conveyor systems utilize unoccupied ceiling space, freeing up valuable floor area for core operations. These systems can operate on a single motor for long distances, such as 500 feet with turns and elevation changes, and minimal maintenance needs.  

Some Key Advantages: 

• Lower Capital and Operating Costs: Compared to MDR systems that require multiple motors, sensors, and lift gates, monorail conveyors offer a moderate CapEx and minimal ongoing maintenance. 
• Space Saving Footprint: Monorail systems use overhead paths, preserving ground-level space for productive picking and associate movement. 
• Decoupled Carton Flow: Unlike MDR systems, monorails keep empty carton induction separate from product takeaway, maximizing throughput and system efficiency. 
• Custom Carriers: Carriers can be engineered to accommodate specific carton sizes and shapes, reducing carton damage. 

Want to see a side-by-side breakdown of the three methods? 

Download the Business Case PDF to compare overhead monorail, MDR, and manual carton induction across all major criteria: investment, space, labor, maintenance, and more. This downloadable guide is ideal for anyone evaluating automation strategies for carton/tote delivery. 

Overhead Monorail systems offer a compelling balance of cost efficiency, space savings, and minimal maintenance, making them a smart choice for high-performance warehouse environments. MDR systems are effective in integrated setups but can become a bottleneck when shared with carton induction. Manual carton erection remains labor-intensive and space-inefficient, best suited for operations with minimal throughput needs. 

If you are considering automation solutions for your carton induction process, overhead monorail conveyors present a scalable, cost-effective, and space-saving alternative that can significantly improve operational flow and ROI. 

At Pacline, we know that small, smart innovations can make a big difference in daily operations. That’s why we’ve introduced a new Chain Tension Indicator window located on the take-up assembly expansion unit for the PAC-LINE™ enclosed track overhead conveyor system. The new feature is designed to make routine maintenance faster, easier, and more effective. 

Why Overhead Conveyor Chain Tension Matters 

Over time, the chain on an overhead conveyor elongates due to chain stretch. This gradual stretch will reduce tension in the system, leading to improper operation, increased wear on components, and even unexpected downtime. The take-up unit’s springs help counteract this tension loss, but these springs have limits. Therefore, periodic chain tension adjustments are essential for maintaining optimal conveyor performance. 

A Simple Way to Stay Ahead of Conveyor Chain Maintenance 

To make maintenance easier and more intuitive, Pacline has introduced a Chain Tension Indicator window as part of our conveyor chain take-up unit. The feature provides maintenance personnel with a visual queue for assessment of chain tension using a color-coded sticker system: 

Immediate attention is required to restore proper tension

One of the most significant advantages of the Chain Tension Indicator window is that it eliminates the need for maintenance staff to physically access the take-up expansion unit to check chain tension. This is especially helpful when the unit is installed in hard-to-reach or elevated areas. You also don’t need to be a maintenance technician to spot potential issues. 

Unlike generic indicator lights on a system control panel, which can be vague or misinterpreted, this window provides a direct, visual status. With clear green, yellow, and red color coding, anyone can instantly understand the tension condition without tools, guesswork, or ladders, making inspections faster, safer, and more efficient. 

Easy Retrofit for Existing PAC-LINE™ Systems 

Do you already have a PAC-LINE™ system in operation? No problem. We offer a simple retrofit kit, a bolt-on assembly that converts your existing take-up unit to the new style featuring the Chain Tension Indicator window. Installation is quick and straightforward, with no need for welding or custom modifications. Contact us to purchase a retrofit kit and bring the latest maintenance convenience to your existing system. 

Committed to Continuous Improvement 

By listening to customer feedback and understanding the demands of industrial operations, we develop practical solutions that can reduce unplanned downtime, maintain smooth operations, improve safety, and extend equipment life. The new Chain Tension Indicator reflects that commitment, a low-cost, high-impact feature that brings greater transparency and ease to your conveyor maintenance routines.

As manufacturers gear up for growth in the United States, many are modernizing operations with facility automation. Whether establishing new plants or upgrading existing production lines, there has never been a more strategic time to invest in conveyor systems.

At Pacline, we’ve spent over 45 years engineering and installing overhead chain conveyor systems that solve real-world challenges in manufacturing environments. If you’re scaling operations, upgrading outdated infrastructure, or designing a new plant from the ground up, we have a conveyor solution for you.

Engineering Efficiency from the Ceiling Down

Unlike traditional floor-based systems that consume valuable real estate, overhead conveyors maximize vertical space. Our solutions allow manufacturers to build more optimized workflows, reduce congestion on the floor, and enable continuous, non-stop movement of parts and assemblies throughout the facility.

From single-line synchronous conveyors to sophisticated power and free systems that offer asynchronous movement, Pacline systems are tailored for precision control and adaptability to simple or complex paths involving inclines, declines and turns.

Designed for Modern Manufacturing Demands

Whether you’re automating assembly lines, finishing processes, or material storage and retrieval, PACLINE conveyors are purpose-built to perform in industrial environments.

With millions of feet of conveyor installed, PACLINE has become the trusted partner for manufacturers in automotive, aerospace, electronics, appliance, furniture, and more.

Now is the time to take advantage of PACLINE’s conveyor solutions and build a smarter, faster, more efficient manufacturing operation. Contact our team today!

Pacline Conveyors partnered with an integrator to help a wheel rim repair shop automate their finishing process. By integrating the high-capacity floor-mounted slot sideways Pac-Max™ conveyor with other finishing equipment, the facility transitioned from a manual powder coating system to a fully automated solution.  

This case study highlights the successful deployment of Pacline’s conveyor technology, enabling precise, high-quality finishes for various wheel rims. 

The Challenge 

The end-user wanted to automate their wheel rim finishing process. Previously, they manually placed rims on racks and then moved them throughout the facility to be hand-painted, which was labor-intensive and prone to inconsistencies.  

Therefore, they sought to fully automate the process to improve production efficiency and reduce labor costs. One of the major requirements of the system was to have the rim spin at high speeds yet still be able to attain a precise and even finish on the rims. The automobile wheel rims were of various sizes, reaching a maximum of 26” diameters and 12” height, which the system had to be able to handle.  

The Solution 

Pacline, working with an integrator, developed and installed a customized conveyor solution using a slot slideways Pac-Max™ conveyor system. The system totaled 112 feet and was installed 20″ off the ground, all floor-supported.  

Pacline designed a sprocket rotator and spindle to accommodate various sizes of rims. The first part of the finishing process required the rims to travel through a pre-heat convection oven that required no part rotation and had the conveyor travel at 2 feet per minute speeds.  

Then, the rims travel through a powder-coating spray booth. When they reach the spray booth, the sprocket rotator engages with a powered rotator to allow the operator to customize the speed at which the rims rotate, ensuring that multiple coats can be applied evenly and quickly depending on the size of the rim. Since the powered rotator is driven by a separate motor and controls, the conveyor speed is not affected by any changes to increase or decrease rotation speed.  

The Result 

Pacline completed the conveyor installation in five days, as our integrator was responsible for all controls and electrical work for the entire system, including our conveyor.  

The automated system significantly improved the efficiency of the facility’s rim-finishing process. With the powered rotators, the operator could now customize the rotating speed through powder coating, thus shortening the spray time drastically compared to manual spraying. The production rate accelerated by averaging 5-8 full rim revolutions per minute utilizing the powered rotator, and the new system ensured a more consistent, high-quality finish. Ultimately, the facility reduced labor costs and improved rim finishing quality.  

Overall, the slot-sideways Pac-Max™ conveyor integrated seamlessly into the automated finishing system the integrator had designed to minimize manual handling and maximize production throughput​​. 

For Order Fulfillment operations requiring manual picking and consisting of a low-to-moderate number of SKUs, Pick Modules with order picking Associates are an effective solution. “High runner” SKUs tend to be placed on Level 1, with Low runners on higher levels. Associates typically pick individual items “eaches” out of gravity flow racks and pack them into corrugate cartons for shipping. This increases productivity, since order picking Associates are also packing the shipping cartons.

Efficient empty carton induction into Pick Modules is crucial for optimizing order fulfillment operations, such as in large-scale e-commerce environments. The method you choose for delivering empty cartons can significantly impact productivity and operational efficiency. Here, we explore three common methods for empty carton induction to Pick Modules, highlighting the benefits of using an overhead conveyor system.

Option 1: Manual Handling of Flattened Corrugate

One traditional approach involves storing flattened corrugate at the ends of each Pick Module level. Associates must walk over to retrieve the flats and build the cartons as necessary. While straightforward, this method introduces inefficiencies. Associates often must leave their workstations to retrieve materials, which reduces the time available for picking activities.

Flat corrugate must be stored elsewhere in the warehouse and then transported to each level of the Pick Module using forklifts or carts. This causes unproductive or inefficient movement of equipment, referred to as “deadheading”, as material handling equipment must bring over flat corrugate and load it to different Pick Module levels.

Option 2: Using MDR Conveyors for Pre-built Cartons

Another method involves using Motor-Driven Live Roller (MDR) conveyors to induct pre-built cartons into the Pick Module and then route them to needed zones using Pick-and-Pass/Zone-Routing technology. In this scenario, the cartons are built outside of the Pick Module, either manually or using an automatic case erector.

However, this approach presents some challenges. Transporting empty cartons on an MDR can cause damage to boxes during conveyance or transfers, which often leads to misalignment. Lack of alignment and carton damage can create more challenges for accurate label reading, resulting in misrouting of cartons downstream.

Also, this method takes up some of the MDR capacity for empty carton induction. When empty cartons must be presented to higher levels of the Pick Module, they will have to share the MDR conveyor with filled cartons, reducing order processing capacity. While more automated than manual handling, this method still poses risks and limitations, particularly concerning carton integrity and processing speed.

Option 3: Overhead Conveyors (Monorails) for Empty Carton Induction

Conclusion

Selecting the right method for empty carton induction is critical to the efficiency of order fulfillment operations. While manual carton-forming and MDR-only systems are commonly used, they often come with limitations that hinder productivity. Overhead conveyors, on the other hand, offer a superior solution, ensuring that empty cartons are delivered efficiently, ergonomically and without damage.

At Pacline Conveyors, we specialize in overhead conveyor solutions designed to optimize your order fulfillment operations. Whether you’re looking to enhance productivity or streamline your workflow, our systems provide the reliability and efficiency you need to keep pace with the demands of modern distribution centers and warehouses. Contact us today to speak with an Engineer about a custom-tailored solution.

In the competitive world of party tent rentals, efficiency is key, especially during peak seasons. Managing the drying of large fabric tents can often become a significant operational bottleneck, leading to delays and potential loss of revenue. PACLINE offers a tent drying conveyor solution to streamline operations, enhance productivity, and optimize space utilization. 

The Importance of an Efficient Tent Drying System 

For high-volume tent rental companies, quick and efficient turnaround is essential. After each event, tents must be cleaned and thoroughly dried before they can be reused and rented. Traditional drying methods occupy valuable floor space and extend drying times. This can lead to moisture retention, increasing mold risk and mildew. An effective tent drying system is crucial for maintaining the quality and availability of your rental inventory. 

Why Choose PACLINE’s Tent Drying Conveyor Solution? 

PACLINE’s tent drying conveyor system provides a professional and efficient solution to the challenges of tent drying. Here’s how our systems can benefit your operations: 

The PAC-LINE™ enclosed track conveyor can handle loads up to 50 lbs. per pendant and multiple pendants can be used with clamps to hang the tents depending on their weight and size. These systems are highly customizable to meet the specific needs of your operation, with options for different incline angles, layouts and speeds. Using wooden clamps, like clothes pegs, 4’ centers accordion the tents between, varying size and weights and thickness  

4. Cost-Effective Automation 

Automating your tent drying system with PACLINE conveyors can significantly reduce labor. Once tents are loaded onto the conveyor, the system handles the drying process automatically, allowing your staff to focus on other essential tasks. This automation leads to more consistent operations and reduces downtime between rentals. 

Invest in Your Business with PACLINE’s Tent Drying Conveyor System 

Purchasing a tent drying conveyor system is an investment in efficiency, reliability, and scalability for your party rental operations. Our tent drying systems help you maintain a competitive edge and improve your bottom line by reducing drying times and optimizing space. 

Contact us today for a customized solution and to learn more about how PACLINE can enhance your tent drying process. 

In distribution centers and warehouses, where space optimization and streamlined processes are essential for peak efficiency and productivity, traditional methods of empty carton and tote movement can sometimes struggle to meet the dynamic needs of the environment. Overhead conveyor systems, often referred to as monorails, provide an effective solution to these challenges. They elevate the process quite literally, using the often under-utilized overhead space. Below is a list of seven advantages overhead monorails bring to distribution center and warehouse operations.   

1. Occupies Unused Overhead Space and Frees Up Floor Space 

One of the most significant advantages of integrating an overhead monorail system is its ability to utilize the often-overlooked overhead space. Unlike other carton delivery and removal methods that consume valuable floor space, overhead monorails free up the ground for more critical operations. This not only improves the flow of movement within the facility but also enhances safety by reducing clutter and potential tripping hazards.  

2. Centralized Storage of Corrugate and Loading of Empty Cartons 

Efficiency in distribution centers is heavily dependent on the streamlined handling of materials. Overhead conveyors facilitate the centralized storage of corrugate, simplifying the process of loading empty cartons. This centralization minimizes the time and labor required to manage these materials, leading to more efficient operations.  

3. Allows for Empty Carton Delivery at an Ergonomic Height 

Ergonomics plays a pivotal role in maintaining a productive and healthy workforce. Overhead conveyors are designed to deliver cartons at an ergonomic height, minimizing the need for excessive bending or stretching. This enhances worker comfort and significantly reduces the risk of injury, contributing to a more satisfied and efficient workforce. 

4. Custom Designed Carriers to Maximize Delivery Rates 

Every distribution center has unique needs based on the size and type of cartons handled. Pacline offers custom-designed carriers tailored to maximize delivery rates for specific carton sizes. 

5. Modular Components for Ease of Expansion and Modification 

The needs of a distribution center can rapidly change, necessitating flexible and adaptable solutions. The PAC-LINE™ enclosed track monorail is modular, allowing easy installation, expansion and modification. This modularity ensures that the system can grow and adapt with the business, providing a long-term solution. 

6. Compact and Low-Profile Design to Allow for Versatile Routing 

Space optimization in distribution centers isn’t just about using vertical space; it’s also about intelligently navigating around existing structures and equipment. The compact, low-profile design of PAC-LINE™ overhead conveyors enables versatile routing options, ensuring that the system can be integrated into a variety of spaces without requiring significant alterations. 

 7. Easy to Maintain 

Maintenance is a crucial consideration for any equipment in a distribution center. Overhead conveyors are engineered for ease of maintenance, with simple procedures for chain tensioning and lubrication. This ease of maintenance ensures minimal downtime and consistent operational efficiency. 

An overhead conveyor system is a cost-effective investment in operational efficiency, safety, and scalability to optimize empty carton handling processes. Contact us today to speak with one of our Engineers!  

The Challenge

In the competitive world of distribution and warehousing, efficiency and optimization are key. A leading bathroom and kitchen fixtures company faced a significant challenge in their new Las Vegas distribution center: how to streamline the delivery of empty boxes to packing areas. The traditional manual methods were time-consuming and labor-intensive, leading to bottlenecks in the packing process. Additionally, the distribution center needed to comply with seismic equipment requirements. The goal was to find a solution that could integrate seamlessly with their AutoStore system and improve overall efficiency while considering the safety and ergonomic needs of the workforce.

The Solution

Pacline in collaboration with a trusted integrator known for warehouse optimization, engineered and installed a 600′ monorail system. This system was designed with the PAC-LINE™ an enclosed track with bolt-together construction, ensuring easy installation. The conveyor was strategically positioned alongside the AutoStore system, running above equipment to save floor space and descending to an ergonomic level at packing areas for easy access by workers.

One of the key innovations of this project was the development of a custom double hook carrier, tailored to accommodate four different sizes of boxes used by the client. This flexibility ensured that a range of box sizes could be transported efficiently without the need for manual adjustment or intervention. The system’s variable speed control, capable of running between 12-60 feet per minute, allowed for adaptability to varying workflow demands.

The Result

The automated delivery of empty boxes to the packing areas significantly reduced manual labor, accelerated packing processes, and minimized bottlenecks. The ergonomic design of the conveyor path at the packers’ areas improved worker comfort and efficiency, reducing the risk of strain and injury.

Moreover, the custom double hook carrier proved highly effective in handling different box sizes, enhancing the system’s use. The variable speed feature allowed the operators to adjust the flow of boxes according to real-time demands, further optimizing their operations. As a result of this project, the client witnessed an improvement in overall efficiency.