Due to a large growth in order volumes, the NHS identified the need to improve efficiency in both picking times and transit times to not just cope with present day levels but to allow for future expansion.  

As part of the bidding process, CSL had to present design proposals in accordance with the stringent NHS supplier specifications and Health & Safety policy, as well as providing equipment specifications and detailed recommendations of how the installation would be project managed in conjunction with the main building layout. The new specification required a versatile system to handle both tote bins and plastic trays through five picking zones and down the spiral lowerator to a ground floor packing/dispatch area.  

As part of the design process, CSL’s ability to provide a well demonstrated solution was key to meeting the brief and winning the contract. This included using the latest 3D CAD drawing software to help visualise the system as a life-like operational representation of the customer's building. CSL incorporated some elements of the original system, as it was still in perfect working order and therefore contributed to the ROI. 

The new picking system begins in front of three vertical storage towers, whereby the empty tote/tray has a barcode label applied with a tote/tray ID number and any products from the vertical storage system are placed into the relevant container.

Once the tote is released onto the conveyor system, an initial scan of the barcode is carried out using a Cognex vision camera to validate the integrity of the code, with any no-read/failures routed to a reject lane, separate from the main system for manual identification and re-routing. All good reads are sent to the main picking line on the mezzanine via a series of conveyors and 90° right angled chain transfer. 

The picking operation was designed to function as a zonal pick system, to which CSL incorporated several off-line powered roller sidings which run both parallel and side-by-side with the main transit line.  As picking accuracy for health products is paramount, at each of the sidings the totes are re-read and validated by an additional barcode reader mounted to read the code on the front face of the totes. Each code is checked against a static look-up table and transfers the totes into the required pick zone siding. Once products from that area have been picked, totes are manually pushed back onto the line for re-distribution to other zones or completed orders automatically fed to the spiral for feeding down to the ground floor despatch.

CSL provided optimum workflow and efficiency in order picking and fulfilment to meet the demands of a site operating 24 hours per day. With similar project experience involving mezzanines and installation of more than 100 spiral conveyors throughout various industrial sectors in the UK, CSL’s experience and competitive system designs provided the confidence and commitment for the National Procurement – NHS Distribution Centre to award the contract.

An NHS Spokesperson commented: “We have worked with CSL previously and after many years of reliable operation we decided to use CSL again to design, supply and carry out the installation. As with the last system the benefits became evident almost immediately.”