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. 

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!

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!  

What is a Factory Acceptance Test (FAT)?

For automation projects, a Factory Acceptance Test (FAT) is conducted at Pacline’s factory to verify the performance of the automation cell before it is shipped to your facility for installation. The test ensures that all customer design requirements are met while adhering to safety standards. 

FAT Process at Pacline

During the Factory Acceptance Test, Pacline replicates site conditions and use cases over an extended period in order to identify and address potential improvements. Ensuring safety while meeting production rates is Pacline’s primary consideration. The FAT is the final phase before equipment is dismantled and shipped to your facility for the Pacline crew to install.

Once again, The Hudson’s Bay and Pacline Overhead Conveyors have partnered to produce a creative window display conveyor at the Queen St. Flagship store for Father’s Day.

A creative window display conveyor, if done right, can stop traffic and grab the attention of your target audience. And if you really want to catch the attention of all the people who pass by your store, you’re going to have to do something out of the norm.

For The Hudson’s Bay, this meant using four large street-facing windows to create a unique and animated display. Father’s Day gift ideas were conveyed throughout the windows, catching the attention of pedestrians and commuters passing by.

“Gifts for Dad @Hudson’s Bay  Sharing our latest windows at our Queen St. Flagship store.  Great partnership with Pacline Overhead Conveyers here in Ontario!”

Ana Fernandes (Creative Nat. Director Hudson’s Bay)

Pacline Conveyors is very proud to sponsor Inverse Paradox, a team from Mississauga, Ontario for the FIRST Robotics Competition.  Inverse Paradox consists of over 50 high school students and mentors who work together to build a 120-pound industrial strength robot!

Established in 2004, the team has won many prestigious awards and is known internationally for its amazing team spirit, excellence in robot design, and community and global outreach.

The FIRST Robotics Competition is a fun, challenging, and inspiring science and technology program for kids grade 9-12. The competition was founded by Dean Cumin and was designed to foster 21^st century life skills and spark interest in the following categories:

• Science
• Technology
• Engineering
• Math

Teams of high schoolers are given 6 weeks to design, build, and program a robot capable of playing a challenging field game with and against other teams and robots. Combining the excitement of sport with the rigors of science and technology gives students the opportunity to participate in the “ultimate sport for the mind”. The First Robotics Competition involves approximately 3650 teams and over 90,000 participants!

Congratulations to Team 1325 – Inverse Paradox for all their successes:

• York University District Event – WINNER
• Georgian College District Event – WINNER
• FIRST Ontario Provincial Championship – WINNER
• 2 Chairman’s Awards
• Industrial Design Award sponsored by General Motors
• FIRST Championship Archimedes sub-division – Semi-Finalists

We look forward to seeing what you accomplish next!

Safety in the workplace is more than a slogan. It’s a mantra sung by businesses all over the world in an effort to protect workers and prevent rising health insurance costs and sometimes fatal lawsuits.

Accidents happen and seem to do so at the most inopportune times. Mishaps can pop up involving new and old equipment. With new equipment it’s often due to bad manufacturing and installation; with old equipment, it’s a result of wear and tear that was not recognized and the lack of a stop-gap measure as a precaution against an accident.

There are two specific safety issues here to discuss:

1. When standard manufacturing without safeguards causes harm; and,
2. When there’s equipment failure by design.

Let’s address these in order and why garment conveyor safety is important.

First, do your garment storage conveyors meet USA OSHA (Occupational Safety and Health Administration) regulations? Garment Conveyors? OSHA Regs? Really? Sure thing!

On any machine where there are moving parts within reach of humans who interact with the machine, there must be safety precautions to prevent injury.

https://www.osha.gov/machine-guarding

Case in point: order storage conveyor, the inmate property storage system, and the hotel/casino employee uniform storage and retrieval conveyors.

There are two types of conveyors in this industry:

• open sprocket drive systems with yokes and
• enclosed track systems.

The majority of these conveyors in the United States use idler and drive sprockets on ends and corners of the conveyors along with a “chain” which is suspended from a “track” with “yokes” and wheels. Before we go any further, a few definitions:

Slotted Racks: This is the part of the conveyor on which garments are hung. These are approximately 12 inches in length and typically have 5 – 10 spaces about 1 – 2 inches wide. These “racks” act as chain links and are hinged together with pins that hold the two-wheeled yokes.

Yokes: These are in a “Y” or “V” shape and are attached perpendicular to the chain at the pins with one leg of the “Y”  or “V” facing outward and the other leg of the “Y” or “V” facing inside. On the end of each leg is a nylon wheel that sits at a 45-degree angle. These wheels ride on the:

Track: Round tubing of varying thickness in the shape of the overall conveyor. If it’s a straight conveyor, the tubing starts at a front idler and proceeds around the front curve, to the far end and around the drive sprocket and then back to the front idler sprocket.

Sprocket: A sprocket is a sprocket, teeth and all! It interacts with the chain and when the drive is engaged, the chain rotates around the track. The sprockets are supposed to keep the chain from jumping off the track, which can also be an ongoing issue – we will address that in a future blog.

So, where does OSHA come in?

All conveyors from the major suppliers include track sections that, at some point, are just 72-inches (6-feet) max off the floor.  For the yoke style conveyors, this is usually the idler sprocket end and if the system is flat or single-tier, the entire track will be just 6 feet above floor level. The safety issue here is that anyone around the conveyor could inadvertently grab the track to prevent a trip or fall or lean on it without thinking.

Yoke style conveyors have exposed wheels that create dangerous pinch pints.

These overhead conveyor safety guards usually come at an additional cost of a minimum of $450-$500 USD for the initial install at the idler plus about $20 USD per foot for additional sections of safety guard. This is a costly solution but better than OSHA fines and penalties if caught without them or if harm comes to an employee or customer.

The sprockets also need overhead conveyor safety guards when exposed which is usually on the inside of L-sections. There’s a cost to this as well – about $450-$500 USD minimum.

The other major conveyor type used for garment handling systems are those with an “enclosed track” design.

This can be seen with the PACLINE overhead conveyor systems. Enclosed tracks are excellent for garment conveyor safety as there are no yokes with wheels or sprockets. This type of conveyor is designed with the moving chain moving inside an enclosed track. This feature prevents the type of accident attributed to yokes and wheels. They do not use sprockets at all. The PACLINE conveyor design also allows for easy installation in overhead areas or small spaces to further minimize human contact with any moving parts to prevent possible mishaps. 

Operators are protected from contacting the moving chain with the PAC-LINE™ enclosed track system.

Now, let’s look at safety issue #2.  As mentioned way back in the third paragraph: equipment failure.

Conveyors with chains, yokes and wheels have several breakpoints. The chain—made of aluminum or steel—can break; snap in the middle of a link or at the hinge point. A yoke, because of stress, can crack and fall apart. Also, the wheels can wear out. In each case, the failure can happen at any moment while the drive is operating and the chain is moving around the system. On a flat or level conveyor system, and to a greater extent on a conveyor with an incline of 30, 40, or 60-degrees, when the chain breaks and dislodges itself from the track, disaster can strike.

A break in the chain with the yoke-style conveyor can cause the entire chain to run free of the track resulting damage and possible injury to operators near the system.

This is called a “runaway chain” – the chain just keeps on moving, bunching up as it heads to the bottom of the incline. All along the way, garments on hangers fall to the wayside. Basically, you will experience a system in disarray because the chain had no place to go except off the track. It’s probably the most common failure of this type of conveyor.

After a thorough analysis of your requirements, PACLINE prepares detailed overhead conveyor layout drawings for your approval.  However, should you wish to prepare your own overhead conveyor layout drawing, please use the following as a guideline:

1. Locate overhead conveyor path. Keep parallel conveyor paths as close as possible to simplify installation.

2. Locate equipment, workstations, aisles, columns, walls, load and unload areas, etc.

3. Make a material flow diagram indicating the quantity of material to be handled per minute or hour.

4. Determine the most convenient weight and/or the number of pieces to be handled per carrier to establish tentative carrier size and shape.

5. Determine the number of carriers per minute or hour.

6. Determine the method of attaching overhead conveyors or supports to your building.

7. Determine the maximum incline angle for vertical curves.

8. Select horizontal curve radius. (Curves 24” radius or larger will reduce chain pull)

9. Verify all clearances, both horizontal and vertical.

10. Select tentative track elevations with respect to the bottom of the track.

11. Draw overhead conveyor layout to the largest possible scale. Indicate north direction.

12. Allow a minimum of 8” straight between tangent and vertical and/or horizontal bends.

13. Calculate total chain length. For calculation of chain length on horizontal plane, compute straight dimensions to include all curves. For chain length calculation in vertical inclines, refer to elevation change charts.

14. Always position your drive at the highest elevation to pull the load.

15. Always position the take-up at a low point directly after the drive and avoid curves between the drive and the take-up.

16. Always allow a safety margin when choosing hanging centers.

Contact us, a world-leading overhead conveyor company, for any further inquiries and/or additional information regarding the steps for preparing your layout.

Economical gas mileage is an enticement to buy a hybrid. Getting 50 miles per gallon is attractive. However, while the hybrid looks good on fuel, the return on investment is simple sticker shock, here’s the math. At 50 miles and $2.50 per gallon, the annual fuel cost for the hybrid—at 15,000 miles a year—is $750. For a car that averages 25 miles per gallon, the annual cost of gas is $1,500 a year. It makes sense to buy the hybrid. However, hybrid cars are expensive and can sell for $15,000 more than the same non-hybrid model. At that difference, it will take 20 years to recover the hybrid, not a very good Return on Investment (ROI) to help the environment.

For business, an ROI for capital purchases of 2-3 years makes a lot of sense. With manufacturing and operating automation used to decrease labor costs, determining the uniform conveyor’s ROI is relatively easy. The operation of a hotel uniform distribution room may need to serve 800 employees who pick up and drop off uniforms on a periodical basis. Assume the room that stores and distributes the uniforms is open six days a week, 16 hours a day or 112 hours a week. There’s a room supervisor, one or more seamstresses and other staff to meet and greet employees. There could be as many as six employees in the room. At an average rate including all benefits of $14 an hour, that’s an annual operating budget of $175,000 a year.

Through automation, the staff could be reduced to 10 hours a day, or 70 hours a week, resulting in three or fewer employees. With three, there’s an annual savings of $87,500, about the cost of one system to serve 800 employees which would make the uniform conveyor ROI one year. That’s a little too aggressive because one system may not be enough. Even at two systems, or an investment of $175,000, the uniform conveyor ROI is two years.

Every situation is different. For uniform distribution, there may be fewer garment room personnel. Uniforms may be cared for by employees. There are other variables to consider such as the annual purchase of uniform inventory. And, if automation is being considered at the outset, at the design phase of a hotel, consideration must be given to eliminating fixed lockers for employees and using personal locker bags hanging on a uniform distribution system. It’s a trade-off of space for space and equipment, but for operating budgets, the investment is well worth it.

When making capital purchases, considering price alone does not tell the whole story. Consider the savings and how long it will take to recover the investment. And, remember, once the investment is recovered, it’s like putting money in the bank.

Pacline Overhead Conveyors assist hotels with Return On Investment calculations when considering automation. We will design and price a uniform conveyor system especially for your project, utilizing available space and calculating efficiency and savings. We offer unique systems that require minimal maintenance and unparalleled safety factors and a value that’s quick to recover. Watch the video: Automated Uniform Conveyor System and reach out to us.