This company's unique operation is dependent on maximum product throughput to be competitive with the single step process that is common in the industry. They reached a point where their mailing operation was generating a negative impact on the company's throughput and knew they had to do something about it.

Prior to the new Hytrol system, the only automation in the building was nine slider-bed conveyors receiving product from the discharge end of nine presses. Product was bundled and banded, then placed into a tote or box and palletized directly off these units. The new system removed manual handling obstacles and allows maximum output while maintaining mail date schedules.

Improved Product Flow

This new system is much more efficient and the whole operation is automated. As they anticipated, the mailing automation system has improved product flow within the facility, improved working conditions, and allowed flexibility in scheduling that had not been afforded in the past.

The Hytrol Model SC horizontal belt sortation conveyor provides a reliable method of tracking and sorting the company's direct mail packages. The sorters feed into seven Hytrol Model 190-ACC sort lanes and one 190-ACC overflow line where the product is banded, strapped, sealed, shrink wrapped, and palletized.

Product (printed direct mail pieces) is placed into totes or cases and manually loaded onto Hytrol Model 190-ABEZ (live roller zero-pressure conveyor; EZLogic™) and Model ACC (horizontal power accumulating conveyor) which feed nine continuous vertical lifts (photo at left). Lifts feed into ceiling hung 190-ABEZ conveyors (photo above) that move product to the back of the facility where it is declined and fed into two SC sorters.

Multiple Benefits Realized

• Increased buffer from possible press slowdown or shutdowns due to mail processing.
• More room for product processing
• Increases throughput opportunities