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.