The brief was to provide a semi-automated order picking and stock replenishment system over two floors, with fully reversible capability. It had to stop product between floors for consolidation. CSL delivered a space efficient system, featuring a ‘bolt-on approach’ for future integration to a new WMS, including barcode reading, moving this forward to a fully automated system.

The small items and spare parts being handled are transported in totes, providing uniformity to fit CSL’s standard tote conveyor systems and spiral elevator/lowerator.

CSL’s approach required neither additional guarding nor complicated controls. It incorporates two spirals, stacked on each other to operate as one solution. They provide an infeed and outfeed from the first floor and deliver to the ground or second floor using the same conveyors. 

From the second floor, totes are conveyed to the first floor via the top spiral lowerator. Here, a manual sort determines whether the tote requires removal or placing onto the next conveyor and spiral lowerator to be taken to ground level, where another manual sort takes place. On order completion, complete totes are conveyed to the end of line packing operation for despatch.