Get more from your existing system
As warehouse and distribution operations evolve, the automation that once perfectly matched your requirements may eventually begin to show its limitations.
Perhaps throughput has increased. Product ranges have expanded. Your warehouse layout has changed or perhaps your older conveyor system simply isn’t delivering the performance it once did.
But upgrading doesn’t always mean starting again.
With the right approach, an existing conveyor system can often be modified, enhanced or upgraded to improve performance, increase capacity and support the changing needs of your operation.
When is it time to upgrade your conveyor system?
There are several signs that your existing conveyor infrastructure may need attention:
Capacity is increasing.
As order volumes grow, your conveyor system may become a bottleneck. Increasing conveyor speeds, adding additional lanes or introducing new technology can help increase throughput without requiring a completely new installation.
Your operation has changed.
New products, different packaging formats, changes to order profiles or a redesigned warehouse layout can all create new demands on an existing conveyor system.
Equipment is becoming outdated.
Older motors, controls, sensors and other components can become increasingly difficult to source and maintain. Replacing key components can improve reliability while extending the useful life of the wider system.
You need greater efficiency.
Even if a conveyor system is still operational, it may not be operating as efficiently as it could. Upgrades to controls, drives, sensors or conveyor technology can help improve system performance and reduce unnecessary downtime.
Your business is growing.
A system designed for yesterday’s volumes may not be capable of supporting tomorrow’s operation. Strategic modifications can provide additional capacity and create a more scalable solution.
Upgrade rather than replace
Replacing an entire conveyor system isn’t always the most appropriate solution.
In many cases, the existing conveyor infrastructure remains fundamentally sound and can be retained while specific areas are upgraded or modified.
This could include:
- Replacing obsolete or inefficient parts such as motors and drives
- Upgrading conveyor controls and PLC systems
- Installing new sensors and identification technology
- Increasing conveyor speeds or throughput
- Adding new conveyor sections or lanes
- Modifying conveyor routes and layouts
- Integrating additional sortation equipment
- Improving accumulation and product flow
- Introducing barcode or RFID identification
- Integrating with WMS, WCS or SCADA systems
- Reconfiguring conveyor systems to accommodate new products or processes
Improving efficiency and throughput
Upgrading individual elements of a conveyor system can have a significant impact on overall performance.
Modern motors, controls and sensors can provide greater control over product movement, while improvements to conveyor layouts can reduce unnecessary product travel and improve flow.
Additional accumulation or buffering can help manage variations in product flow, while upgraded sortation can increase the speed and accuracy with which products are directed to their required destinations.
Replacing obsolete technology
Technology continues to evolve, and some components installed many years ago may eventually become obsolete.
Legacy control systems, drives, sensors and other electrical or mechanical components can become increasingly difficult to support.
Modifying your system for new requirements
Your conveyor system may also need to change because your operation has changed.
Perhaps you’re introducing new packaging formats, adding a new picking process, relocating packing stations or expanding into additional warehouse space.
CSL Automation can assess the existing system and identify where modifications can be made to accommodate those requirements.
This could involve extending conveyor routes, changing product flows, adding transfers, introducing new sortation or integrating additional automation.
A complete approach to conveyor upgrades
The most effective upgrade programmes start with understanding the existing system.
At CSL Automation, we can assess your current conveyor infrastructure, identify areas for improvement and develop a solution around your operational requirements.
Our team can support projects ranging from individual equipment upgrades and system modifications through to larger-scale conveyor enhancements and automation projects.
Importantly, we take an integrator-led, technology-agnostic approach, allowing us to consider the most appropriate technology for the application rather than being restricted to a single equipment manufacturer.
Whether you need to improve throughput, replace ageing equipment, increase capacity or adapt your conveyor system for future growth, we can help you understand what is possible.
Don’t replace what you can improve
A conveyor system doesn’t necessarily reach the end of its useful life simply because your requirements have changed.
With the right assessment and upgrade strategy, existing automation can often be enhanced, extended and adapted to meet new operational demands.
From replacing obsolete components to expanding conveyor capacity and integrating new automation, CSL Automation can help you get more from your existing system.
If your conveyor system is struggling to keep pace with your operation, it could be time for an upgrade rather than a complete replacement.
Contact CSL Automation to discuss your existing conveyor system and find out how upgrades and enhancements could improve performance, increase capacity and support your next stage of growth.
Discuss your Project Requirements
Thank you for your interest in CSL Automation. As one of the UK’s leading conveyor and automation integrators, we can help maintain your automation system.
Start your automation journey today.
