For Order Fulfillment operations requiring manual picking and consisting of a low-to-moderate number of SKUs, Pick Modules with order picking Associates are an effective solution. “High runner” SKUs tend to be placed on Level 1, with Low runners on higher levels. Associates typically pick individual items “eaches” out of gravity flow racks and pack them into corrugate cartons for shipping. This increases productivity, since order picking Associates are also packing the shipping cartons.

Efficient empty carton induction into Pick Modules is crucial for optimizing order fulfillment operations, such as in large-scale e-commerce environments. The method you choose for delivering empty cartons can significantly impact productivity and operational efficiency. Here, we explore three common methods for empty carton induction to Pick Modules, highlighting the benefits of using an overhead conveyor system.

Option 1: Manual Handling of Flattened Corrugate

One traditional approach involves storing flattened corrugate at the ends of each Pick Module level. Associates must walk over to retrieve the flats and build the cartons as necessary. While straightforward, this method introduces inefficiencies. Associates often must leave their workstations to retrieve materials, which reduces the time available for picking activities.

Flat corrugate must be stored elsewhere in the warehouse and then transported to each level of the Pick Module using forklifts or carts. This causes unproductive or inefficient movement of equipment, referred to as “deadheading”, as material handling equipment must bring over flat corrugate and load it to different Pick Module levels.

Option 2: Using MDR Conveyors for Pre-built Cartons

Another method involves using Motor-Driven Live Roller (MDR) conveyors to induct pre-built cartons into the Pick Module and then route them to needed zones using Pick-and-Pass/Zone-Routing technology. In this scenario, the cartons are built outside of the Pick Module, either manually or using an automatic case erector.

However, this approach presents some challenges. Transporting empty cartons on an MDR can cause damage to boxes during conveyance or transfers, which often leads to misalignment. Lack of alignment and carton damage can create more challenges for accurate label reading, resulting in misrouting of cartons downstream.

Also, this method takes up some of the MDR capacity for empty carton induction. When empty cartons must be presented to higher levels of the Pick Module, they will have to share the MDR conveyor with filled cartons, reducing order processing capacity. While more automated than manual handling, this method still poses risks and limitations, particularly concerning carton integrity and processing speed.

Option 3: Overhead Conveyors (Monorails) for Empty Carton Induction

A highly efficient solution is the use of an overhead conveyor (monorail) system to deliver empty cartons directly to Associates at ergonomic heights, in conjunction with using an MDR for take-away. By eliminating the need for Associates to leave their workstations, overhead conveyors maximize picking time and streamline the workflow. Empty cartons are delivered directly to where needed and always presented to Associates in the same orientation, provided they are loaded correctly, meaning there is no misalignment during conveyance. Carton damage is completely avoided as monorail conveyors are ideal for handling empty cartons.

Utilizing a monorail conveyor results in the MDR being dedicated for filled and partially filled cartons (take-away) only. The separation maximizes the efficiency and capacity of the Pick Module, enabling faster order processing.

Conclusion

Selecting the right method for empty carton induction is critical to the efficiency of order fulfillment operations. While manual carton-forming and MDR-only systems are commonly used, they often come with limitations that hinder productivity. Overhead conveyors, on the other hand, offer a superior solution, ensuring that empty cartons are delivered efficiently, ergonomically and without damage.

At Pacline Conveyors, we specialize in overhead conveyor solutions designed to optimize your order fulfillment operations. Whether you’re looking to enhance productivity or streamline your workflow, our systems provide the reliability and efficiency you need to keep pace with the demands of modern distribution centers and warehouses.