Advance SmartLine conveyor increases efficiency at ZyroFisher

ZyroFisher is one of the largest privately owned companies in the UK and Ireland for the distribution of bicycle accessories, spare parts and clothing. It distributes more than 50 leading brands worldwide, while at the same time supplying specialist dealers with its own Altura brand. The company is growing – more than 800 parcels go out every day. High demands on material flow had to be met with an innovative handling system: Advance SmartLine conveyors in combination with energy-efficient 24 V technology and the MultiControl from Interroll.

In the 9,000 m2 plant in Darlington, a lot of work was still required for shipping and packaging. Therefore, the required solution should transport the goods more efficiently from the packing area to dispatch. With the overriding goal of improving order processing, streamlining processes and increasing warehouse productivity.

Transport by roller conveyor to the shipping trailer

As a first step, ZyroFisher Advance commissioned Automated Systems Ltd. to evaluate the existing handling methods. The technicians’ modernization offer was a tailor-made SmartLine zone roller conveyor for transporting cartons of different sizes directly to the shipping trailer.

The next step was the installation of the zero-pressure accumulation conveyor system operated with energy-efficient 24 V technology. Perfectly matched with a quiet running RollerDrive EC310 Drum Motor and MultiControl control. As this is a four-zone controller, it was connected to up to four RollerDrive EC310 and four zone sensors and integrated directly at fieldbus level. It communicates in real time via PROFINET, EtherNet/IP and EtherCAT, which can be implemented with a simple setting on each MultiControl.

Simple and fast commissioning on site

Sensor or RollerDrive properties were configured via PLC software, a web interface or the Interroll teach-in process. With quick and easy on-site commissioning – on the one hand because automatic addressing was possible and on the other hand because the solution provides information on the sequence of all connected MultiControl or conveyor zones in the conveyor. Since no manual addressing or configuration is required, the components can now be easily replaced using plug & play technology.

Independent modules in the conveyor system

Each conveyor module of the Advance automation solution can be operated independently. They remain ready for product transport – only when containers have to be transported do they start moving. If necessary, the product can accumulate along the entire length of the conveyor system. In addition, the conveyor system is equipped with single-width lifting passages for pedestrians and escape routes and double-width for pallets. To ensure simple and safe lifting, gas springs are installed in all passages. An extendable roller conveyor is integrated for loading the trailer.

Most energy-efficient and economical method

Advance Automated Systems’ modernization project fits in perfectly with ZyroFisher’s operations using Interroll’s industry-leading 24V technology and controls. This results in an efficient flow of goods and increased throughput. The Advance SmartLine modular and flexible zero-pressure accumulation conveyor is the most energy-efficient and economical method for conveying cartons directly onto the shipping trailer. An innovative solution that, in combination with the Interroll components used, makes a major contribution to the success of ZyroFisher.