How Modular Conveying Keeps the Supply Chain Moving

Potential global supply chain issues made daily headlines in the final quarter of 2021. But the big question on most people’s minds as they saw those stories was whether they would get their holiday presents on time.

The 2021 holiday season outperformed most analyst projections. Retailers sold more than pre-pandemic years. And the supply chain, which had to meet the growing demands of consumers buying products from ecommerce vendors, held strong. One of the reasons for the strong supply chain was efficiency along every stop, particularly at distribution centers around the world.

Not only have distribution centers had to deal with increased demand, but in the last five years, they’ve had to change the way they operate. Modular conveyors, which excel at parcel sortation, have helped warehouses and distribution centers make this transition successfully and efficiently.

The Economic Impact of Ecommerce

More people have been buying things online in the last few years. The United Nations Conference on Trade and Development calls this rise ‘dramatic,’ with the share of total online sales in 2020 rising from 16 percent to 19 percent. The U.S. International Trade Administration expects that to rise another 8 percent by 2024.

According to the National Retail Federation, 2021 holiday season sales exceeded expectations (and that's including ecommerce). But numbers suggest with COVID-19, online sales figures once only seen as part of a peak holiday season have extended into year-round numbers.

The increase in ecommerce is placing more demand on distribution centers, which not only have to deal with larger volume, but also have to sort and handle a larger variety of package types. Packaging has changed within the last decade and having a sortation system that can’t handle modern packaging will cost an ecommerce business money and time.

The Problem with Traditional Conveyor Systems

Legacy conveyor sortation systems were excellent for dealing with boxes. But if you’ve ordered anything online in the past few years, you may have noticed receiving more items in smaller packages, like polybags or flats. In 2015, the basis for shipping costs shifted away from volume to having the cost determined by package dimensions. With this change, ecommerce sellers started sending more packages in smaller, more cost-efficient packages.

While they’re great for dealing with boxes, in regards to smaller items, such as polybag packages, traditional conveyors are inefficient, error-prone and a potential hazard for distribution center employees. The size of roller-based conveyor systems means smaller items, like flats or polybags, fall through or get caught in the rollers. Additionally, roller systems use pneumatics to perform diversion work. Not only are pneumatic systems loud, but they also place workers who would have to physically clear any jams or fallen items directly in the line of fire. Sortation errors, system slowdowns and injured employees are all very costly for any business.

Modular Conveyors – The Solution to Efficient and Safe Polybag Conveying

Modular conveyors are scalable, flexible and excel at sorting a diverse selection of packaging styles. Conveyors with a smaller belt surface keep flexible packages on the line, rather than letting them fall through the rollers. The ModSort Transfer and Divert Station from Regal Rexnord is a modular conveyor ideal for polybags and smaller packages. ModSort eliminates the need for manual sortation, and does not need workers to put packages into plastic totes for the system to move them along.

Modular conveyors have other environmental and safety benefits. Without pneumatics, modular systems are quieter. Additionally, energy needs are different. ModSort runs off 24-volt DC energy, rather than a three phase motor. And when a worker does need to interact with an item moving down the line, they can manually stop the item safely and efficiently.

Switching to Modular Conveyors

Change is rarely easy. And while changing from a traditional conveyor system to a modular conveyor often depends on a distribution center’s setup, some are able to switch systems over the course of a weekend. Additionally, should needs change in the future, it is very simple to add new pieces on to a modular system. Modular conveyor systems can be quickly and easily reconfigured to handle changes to product lines.

Accuracy and uptime are important in keeping distribution centers profitable. Modular conveyor systems have helped distribution centers keep up with increased demand and get items into the hands of people who need them. Modular conveyors ensure the sortation portion of the supply chain is reliable and flexible.

Because modular conveyors operate smarter, distribution centers don’t need as many employees on the line. With personnel shortages, modular conveyors can move line employees to more value added spots and reduce open position counts at distribution centers.

ModSort – The Modular Conveyor for You

Regal Rexnord’s ModSort Transfer and Divert Station is the industry leader. ModSort is based around motorized drive rollers, using motion control (rather than force) to move objects. Pinch points on the ModSort are minimized, and operation is quieter and safer than traditional conveyors.

ModSort can move everything from small polybags to boxes while integrating with new or existing systems. Used around the world, ModSort can increase uptime and accuracy and add value at any distribution center. Talk with a ModSort engineer to find out how ModSort can help you.