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. 

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 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.