Modular Conveyor Platform: Flexibility for Conveyor Systems

The Interroll conveyor platform features cutting- edge industrial design, both in terms of functionality and aesthetics. All elements fit each other perfectly, allowing easy system modifications or upgrades. The clear design also facilitates quick orientation and makes the interaction between individual elements intelligible.

Logistics: Managing fluctuations in deliveries

These days, customers (e.g. retailers) are increasingly asking for smaller and more frequent deliveries. Instead of entire pallets of goods, they order a few cartons, partly in a "storage ready" format in order to minimize restocking.

This trend towards just-in-time (JIT) processes is further accelerated by the booming global e-commerce sector with its double-digit growth rate. Companies need to provide larger quantities of smaller orders and deal with major order flow fluctuations. In addition, an enormous amount of returns must be processed.

Focus on modular systems

The trend towards shorter order cycles forces manufacturers, distributors, and warehouse operators to be more flexible in their business procedures and therefore also with regard to their conveyor systems.

Often traditional material flow systems, which include conveyor systems, are considered inflexible and not suitable for fluctuating market conditions. Flexible systems with largely standardized components and modules that can be converted quickly, updated easily, and combined with each other are becoming more and more attractive.

Extremely versatile and cost-efficient conveyor systems for maximum availability and rapid adaptation to new requirements

Flexible system configuration

The new generation of conveyor modules offers enormous versatility with straight lines, curves, merges, and transfers that are perfectly coordinated. All these elements can be combined in a modular way, making for swift on-site installations and system assembly. The use of widely available standard components reduces maintenance costs; and no specially trained personnel are required for maintenance.

If order structures, throughput requirements, or product mixes change suddenly, the modular design of the new conveyor platform comes into play: System extensions or modifications are possible without major structural changes. Additional modules can be integrated on site in the existing conveyor line with minimal effort. This guarantees scalability for future growth and a future-proof investment.

Hans-Georg Förster, Managing Director Förster & Krause GmbH, Remscheid, says:

In recent years, energy-efficiency has become an important aspect of all our intralogistics projects. With Interroll's leading extra-low voltage technology and innovative drive systems, we can offer our customers tailor-made solutions that ensure the lowest operating and maintenance costs as well as exemplary low-noise operation. The flexibility and scalability of the new Interroll platform will improve our product and service portfolio further.

Modular Conveyor Platform: Robust and lasting solution

The through and through mechanical design, highly efficient motors and plug-and-play elements of the new generation of conveyor modules are made for robust and lasting systems — the best guarantee for maximum production line availability.

The DC conveyor modules equipped with MultiControl contain the logic for zero pressure accumulation conveying and communicate via network PROFINET, EtherNet/IP and EtherCat. With the help of MultiControl, sensors and RollerDrive are directly integrated at the fieldbus level so that no additional sensor/actuator level is necessary. This provides enormous flexibility - for warehousing as well as for planning and installation of conveyors.

In the end, it depends on investment spending and operating expenses

The relative importance of capital expenditures and operating expenses may vary depending on the company; but when it comes to projects with technology investments, both aspects must be considered together. No matter what key figures are used to compare projects (return on investment, net present value, internal rate of return, etc.): In today's business world, it is more important than ever to make smart decisions when it comes to the plant.

Conveyor Systems: Calculating maintenance costs

With respect to conveyors, this means that in addition to the purchase price, the payment terms, ongoing operating costs, return on investment calculation, and cost factors such as maintenance, installation, and training must be considered.

This is exactly what the conveyor platform aims to achieve: all conveyor modules—from lines and curves to merges and high-speed transitions— are designed to meet the requirements for performance, cost and ease of use. The use of highly efficient drive technology, such as 24V RollerDrive and the elimination of pneumatic actuators are just some of the reasons why the systems have the shortest amortization periods.

Reduced planning complexity and faster commissioning of modular conveyor platforms

The ready-made solutions are based on high-quality components, making project-planning easier and safer. To further promote lean project planning, user-friendly software like the "Layouter" was developed. The modularity of the platform makes it possible to offer the best delivery times in the industry — a key to success for tight commissioning times.

As a pioneer of DC drive technology in intralogistics, the RollerDrive is the most commonly used drive for zero-pressure accumulation conveying. Compared to centralized drive systems, roller driven with the RollerDrive can yield up to 50 percent in energy savings. In addition, the conveyor belts are driven by compact, space-saving drum motors that are much more efficient than conventional drives.

Guaranteeing continuity

The globalization of the world economy, shorter innovation cycles, and higher market transparency make logistics a decisive factor for success. Delivery times are thus often critical in intralogistics and problems in the supply chain can lead to business losses. Reliable partners and suppliers are essential in the battle for market share and customer satisfaction.

Open platforms vs. proprietary systems in logistics

Increasing uncertainty with regard to order structures and volumes as well as the composition of the product mix requires versatile systems that are easily adapted to changing requirements. This requires product platforms that are based on industry standards and thus provide a certain degree of compatibility. Product specialists and manufacturers with these open platforms are becoming increasingly attractive for companies that must have maximum system availability and continuity in the supply chain.

Key facts of the next generation of conveyor systems:

Highest throughput rate of up to 2.5 m/s and 3,600 units/h (e.g., with high-performance divert)
Best delivery times for standard and special solutions as well as local planning support from experienced application engineers
Optional DC or 400 V drives for maximum energy efficiency and conveying capacity
Flexible side guides for seamless adaptation to different goods
Universal side rails for easy installation and flexible system expansion
Electromechanical actuators instead of pneumatic actuators for efficient and low-noise operations
High-speed fieldbus as an open platform and future-proof control system