Modern Materials Handling - February 2011

PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING 

mmh.com 

SPECIAL ISSUE 

February 2011 

® 

CHICAGO, 2011 

Putting productivity 

to work 

SYSTEM REPORT 

Simon & Schuster 

set a textbook 

example 42 

SPECIAL REPORT 

2011 conveyor 

survey 66 

EQUIPMENT 101 SERIES 

Rack basics 60

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UP FRONT Breaking news you should know 

FAST FACT 

23% 

Segment of Modern’s readers surveyed who 

say they plan to spend more on conveyors in 

the next 18 months. See story, page 66. 

PECO pallets now available in Mexico 

PECO Pallet is now shipping its signature red 

wood block pallets to manufacturers and retailers 

in Mexico. In December 2010, it registered 

“PECO Pallet México” as a legal entity and an 

authorized Importer of Record. 

“We are excited about our recent growth in 

Mexico. This represents the next step in our company’s 

service expansion,” said David Lee, CEO of 

PECO Pallet (www.pecopallet.com). 

PECO has established a manufacturing base in 

Mexico, with a plant in Guadalajara that will manufacture, 

repair and 

store pallets. Pallets 

built in Mexico can 

be shipped either to 

the United States or 

Mexico. To comply 

with international 

regulations, PECO 

applies certified heat treatments to all pallets shipping 

into Mexico and also to pallets shipping back to 

the United States. 

Psion drops “Teklogix” from name 

Psion has shortened its operating company name, removing the 

name “Teklogix.” Psion’s corporate identity has also been refreshed to 

work better in the digital world. According to the company, these developments 

mark the next stage in the company’s transformation and reflect 

the group’s business strategy. 

“Our research showed that we had to remove the word ‘Teklogix’ 

from our name, to unite the business around one, clear, global 

identity,” said John Conoley, CEO of Psion (www.psion.com). “We 

found that the complexity of the dual company name was impacting 

our business by confusing our customers, resellers and other key 

stakeholders, 

especially in 

new markets for 

Psion.” 

Psion is No. 8 

on Modern’s Top 

20 ADC suppliers 

list, reporting 

$155.1 million in 

revenue in 2009. 

RedPrairie grows by three 

RedPrairie has RECENTLY 

added the expertise of three software 

companies to its portfolio. 

RedPrairie (www.redprairie.com) 

has acquired: 

• Shippers Commonwealth, a provider 

of software-as-a-service transportation 

management systems 

and collaborative transportation 

solutions; 

• SofTechnics, a provider of integrated 

retail enterprise solutions 

and inventory management solutions 

that has been serving customers 

for more than 20 years; and 

• Escalate Retail, a provider of 

all-channel commerce to specialty 

retailers, direct marketers and bigticket 

retailers. 

Alabama Robotics Technology Park to educate in robotics, automation 

Omron Scientific has partnered with the Alabama 

Robotics Technology Park (rtP, www.alabamartp.org) 

to complete a three-phase project 

that will consist of individual training 

facilities targeted to a specific industry 

need, which will provide college 

level courses on every aspect of 

robotics training, including robotics 

safety. Omron is the primary robotics 

safety provider for the project. 

“The vision of Alabama Governor 

Bob Riley, the rtP is a collaborative 

effort between the state of 

Alabama, Calhoun Community 

College, AIDT, which is Alabama’s workforce training 

agency, and robotics industry leaders,” said Ed Castile, 

AIDT executive director. “The 

mission of the rtP is to provide a 

technically trained, highly skilled, 

and educated workforce for current 

and future automation and 

robotics technologies, to assist 

public and private entities in 

developing new robotics systems 

and technologies, and to promote 

the growth and expansion of 

companies through new robotics 

technologies.” 

mmh.com Modern Materials Handling / F e b r u a r y 2 0 1 1 3

Some things are 

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Quality for today. Durability for tomorrow. 

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Fortunately for you, time has proven one rack has what it takes to survive 

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• Versatility with industry-standard boltless beam connections 

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• Quality construction backed by excellent customer support. 

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VOL. 66, NO. 2 

PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, 

WAREHOUSING AND MANUFACTURING 

® 

COVER STORY 

PROMAT 2011 SHOW PREVIEW 

22 Putting productivity to work 

ProMat 2011, slated for March 21-24, 2011 will showcase more than 

700 exhibits and include a comphrehensive educational conference. 

The event, held at McCormick Place in Chicago, will offer an array of 

products to help improve productivity at your company. 

FEATURES 

SYSTEM REPORT 

42 Simon & Schuster: A twice-told tale 

A warehouse control system and new technology is the hero at Simon 

& Schuster’s New Jersey distribution center. 


51 Productivity Achievement Awards 

Modern’s annual Productivity Achievement Awards honor companies 

that have made outstanding strides in improving operations through 

materials handling and related information systems. 

PRODUCTIVITY SOLUTION 

58 Lean and green pallets 

With a new presswood pallet, Lincoln Electric is not only meeting 

European export requirements and streamlining its pallet inventory, 

it’s reaping sustainability benefits. 

EQUIPMENT 101 SERIES: PALLET RACK 

60 Behind the backbone 

Pallet rack is a fundamental component that can maximize storage 

space and have a positive impact on organization, productivity and 

throughput in your facility. 


66 Reader survey: Conveyor technology 

Conveyors are the most used form of automation in today’s plants and 

distribution centers. Modern readers told us how they’re putting the 

technology to work. 

60 Seconds with... George Prest 

DEPARTMENTS & COLUMNS 

3/ Upfront 

7/ This month in Modern 

19/ Lift Truck Tips: Attachments 

40/ Supplement: Warehouse & DC 

77/ Focus On: Lift trucks 

82/ 60 Seconds with... 

NEWS 

9/ ProMat 2011 ready for 30,000 attendees 

14/ Behind Intermec’s acquisition of 

Vocollect 

15/ ISM’s January manufacturing data shows 

strong momentum to begin 2011 

Modern Materials Handling ® (ISSN 0026-8038) is published monthly by 

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mmh.com MODERN MATERIALS HANDLING / F E B R U A R Y 2 0 1 1 5

MAXIMIZE your company’s productivity, cost savings, 

safety, space usage and sustainability just by visiting 

Booth #1219 at ProMat 2011. 

Sign up to learn more at www.buckhorninc.com/maximizer 

Uncover a NEW kind of 

reusable alternative. 

Booth #1219 

©2011 Buckhorn / Myers Industries, Inc. #012811 

US: 1.800.543.4454 

Canada: 1.800.461.7579 

www.buckhorninc.com

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DIRECTOR 

The importance of being there 

No one is a bigger advocate for 

online education than I am. In fact, 

we’ve built a major portion of Modern’s 

business around online media delivery, 

webcasts and virtual conferences that offer 

a highly valued learning experience that can 

be accessed from the comfort of your own 

facility—or most comfortable chair. 

And while new media has carved out its 

niche in continuing education, the act of 

supplementing that experience with some 

old fashion, face-to-face interaction will 

never go out of style. 

I realize that many readers have been 

grounded over the past two years due to 

budget cuts and the lack of precious time. 

Has it been a couple years since you’ve 

strolled a show floor, shook a few hands, 

saw some of the latest equipment in action, 

or had dinner with a long-time equipment 

vendor or old colleague? 

Well, I’m going to suggest that you pack 

a bag for a few days and get to ProMat 

2011 in Chicago (March 21-24). 

The economic tide is turning, and our 

research is pointing to a renewed optimism 

in terms of materials handling investment. 

According to Modern’s 2011 State of the 

Industry Survey, the timing of this year’s show 

should certainly have the folks at the Material 

Handling Industry of America (MHIA), the host 

of the bi-annual event, smiling from ear to ear. 

Our survey reveals that, while still a bit 

cautious; U.S. businesses are now looking to 

make more long-term investments in their 

materials handling operations and are considerably 

more optimistic about the future 

than just a year ago. In fact, slightly more 

than one-half (51%) told us that they’re 

proceeding with needed/planned purchases 

this year; most significantly, a hardy 22% 

say the current economic conditions are not 

dampening materials handling spending in 

any appreciable way. 

That data should set the table for a rather 

active show floor. In fact, MHIA says it’s anticipating 

more than 700 exhibitors and is 

projecting close to 30,000 visitors. MHIA has 

sweetened the pot a little this year for those 

organizations that may be taking a closer look 

at robotic solutions inside their four walls. 

ProMat will be co-locating with Automate 

2011, an event sponsored by the Automation 

Technologies Council (ATC), that highlights 

the latest robotic vision, motion control and 

automation technologies and systems. 

And while it will be good to assess how 

the latest technology may be applied inside 

your operation, it would be worth your 

while to sit in on one of the more than 80 

educational sessions that the MHIA has 

programmed over the four days. It never 

hurts to brush up on the basics or chat faceto-face 

with peers who are facing similar 

operational challenges. 

It’s also a good time to spend some time 

with us. The entire Modern editorial staff 

along with a complement of contributing 

editors will be covering the show floor for 

the ProMat Show Daily, the print and online 

source for keeping you up to date on all the 

activities surrounding the four-day event. 

I suggest you dig into the closet and 

dust off your suitcase. What you might 

find in Chicago next month could not only 

revolutionize your operations, but help you 

reconnect face-to-face with the people who 

drive innovation in our industry. 

Official Publication of 


New Order Fulfillment Engine 

Elevates Warehouse Performance 

The Dematic Multishuttle solution is an all new 

way to assemble orders. It is the highly efficient 

engine that provides precise load sequencing at 

higher rates, in less space, with more operational 

flexibility. Multishuttle is ideal for supplying 

product to piece pick order fulfillment modules or 

mixed case pallet building operations; it can also 

be applied as a short term buffer storage system 

or as a parts support system for production 

operations. 

Dematic Multishuttle re-defines order fulfillment 

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Increased throughput: 4–7 times greater than 

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High utilization: Feeds workstations with high rates 

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Smaller footprint: Fewer aisles required to obtain 

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More layout options: Fits into overhead spaces, 

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Precise sequencing: Presents loads to pick stations 

or palletizers in exact sequence 

Range of load types: Flex option accommodates 

various load sizes 

Energy efficient: Low voltage carrier uses less 

energy; quiet operating 

Redundancy with back-up: Identical carriers provide 

duplicate service; carriers are interchangeable 

Access to stock: Walkways in the rack aisles allows 

manual back up picking 

Scalability: Add more carriers in future to provide 

more throughput 

To learn more about the Dematic Multishuttle visit ProMat booths 3603 & 3612 or www.dematic.us 

or call 1-877-725-7500. 

Visit Us at Booths 3603 & 3612

Di@blog 

best of Modern’s blogs 

Company Briefings | Bob Trebilcock 

CHEP aims to build the better pallet 

www.mmh.com/blogs 

TRADESHOWS 

ProMat 2011 ready 

for 30,000 attendees 

INDUSTRY TRADESHOW AND EDUCATIONAL CONFERENCE 

WILL ALSO OFFER ACCESS TO AUTOMATE 2011. 

BY NOËL P. BODENBURG, EXECUTIVE MANAGING EDITOR 

IT SEEMS AS IF the Material Handling 

Industry of America (MHIA, 

www.mhia.org), sponsor of ProMat 

2011, had a premonition of this 

winter’s wrath when it moved the biannual 

industry event this year from 

snowy January to March in Chicago. 

ProMat, the materials 

handling industry’s 

premier trade show and 

educational conference, 

will be held at McCormick 

Place South from 

March 21 to 24, and officials 

are getting ready to 

welcome nearly 30,000 

visitors. 

Attendees will find 

more than 700 exhibits, 

two keynotes, two 

educational tracks and 

80 educational sessions 

spread over the 

four days. In addition, 

registered attendees not 

only gain full access to 

ProMat, but also free entry 

into Automate 2011, 

held across the hall in 

McCormick Place North. 

Like ProMat, Automate 

(formerly the International Robots, 

Vision & Motion Control Show) is held 

just once every two years. Sponsored 

by the Automation Technologies 

Council (ATC)—and its trade associations 

Robotic Industries Association 

(RIA), Automated Imaging Association 

(AIA) and Motion Control Association 

(MCA)—Automate will showcase the 

latest robotic, vision, motion control 

and automation technologies and 

systems. 

MHIA and ATC brought the two 

shows together for the first time to 

help visitors maximize their travel time 

and budget. Because of the logical 

fit between the industries and their 

technologies, and the emergence of 

more robotics systems into materials 

handling practices, now seemed like 

a good time to co-locate, said John 

Nofsinger, CEO of MHIA. 

“We’ve always known that the audience 

for the robotics and materials 

handling industries are very compatmmh.com 

MODERN MATERIALS HANDLING / F E B R U A R Y 2 0 1 0 9

ProMat 2011 Facts 

Name of Event: ProMat 2011 

Event Sponsor: The Material Handling Industry of 

America 

Event Dates: March 21-24, 2011 

Event Location: McCormick Place South, Chicago 

Registration: www.ProMatShow.com 

... 

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ible and, because there is little overlap in the memberships 

of our two organizations, very few exhibitors had to 

choose in which event to exhibit,” he added. 

With two shows being hosted in one location, officials 

decided to have not one, but two keynote addresses. 

The first runs Monday morning and features Tom Ridge, 

the first U. S. Secretary of Homeland Security. During the 

presentation, “Fortune Favors the Brave: The Net Gain 

of Supply Chain Security in a Risk-Based World,” Ridge 

will examine the inextricable link between security and 

prosperity for the global supply chain. 

On Tuesday, the second keynote presentation, “The 

Development of Robonaut 2: A Story of Government- 

Industry Collaboration and Technology Transfer for the 

Next Generation of Robotic Solutions,” will feature 

speakers from NASA and General Motors. The two organizations 

will share insights into how they continue to 

work together to accelerate the development of the next 

generation of robots and related technologies for use in 

both the automotive and aerospace industries. 

Co-located events 

In addition to Automate, other organizations affiliated 

with the materials handling and robotics industries have 

seized the opportunity to host events during these four 

days. These include the 42nd International Symposium on 

Robotics (fully integrated with Automate) and the 2011 

Industrial Crane & Hoist Conference (co-located with 

ProMat). 

Further, associations and affiliated groups are hosting 

gatherings to give show visitors the chance to meet 

and learn more about topics specific to their industry in 

private rooms at McCormick Place. These include WERC 

Council of Chicago, The Material Handling Equipment 

Distributors Association (MHEDA), and the National Renewable 

Energy Lab (NREL). 

Education 

Beyond the 700 exhibits on the show floor, ProMat 

offers numerous ways for you to learn something new. 

Eighty free educational sessions will be located in the 

Knowledge Center running from 10:30 a.m. to 4:45 

p.m. Monday and Tuesday, and on Wednesday from

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10:30 a.m. to 3:15 p.m. Topics range from best practices 

reviews to maintenance to metrics. 

“The on-floor seminars are presented by industry experts 

in materials handling and logistics solutions,” says 

Terri Heisey, manager of conference programs for MHIA. 

“It’s a great opportunity for attendees to be educated on 

the latest technologies from exhibitors, industry groups 

and research institutions.” 

ProMat will also feature two half-day educational 

tracks that will provide in-depth coverage on supply chain 

career development and sustainability. 

On Tuesday, from 1 p.m. to 4:15 p.m., a series of 

presentations and panel discussions will examine “The 

People Side of the Supply Chain.” This track will take a 

close look at how companies can succeed at leading the 

people who keep the supply chain moving. In these sessions, 

details will be shared about a variety of available 

resources that will help keep people interested, engaged 

and committed to a supply chain career and to your 

company. 

On Wednesday, from 1 p.m. to 5 p.m., Steve Thomas 

of TV’s “This Old House” and “Renovation Nation” will 

be both speaker and host of several presentations discussing 

“Sustainability, the Supply Chain and Their Future 

Together.” This speaker series will examine what it takes 

to start injecting sustainable practices into the supply 

chain, what is working today and what a sustainable supply 

chain might look like in 2030. 

Show Floor 

With the economy slowly rebounding, exhibitors who 

chose to have a presence at the show will be in prime 

position to help a crowd of attendees that Nofsinger says 

has come prepared to buy. 

“They’re coming to make specific, selected purchases, 

as opposed to just an introduction to new technologies,” 

he notes. Topping the must-see lists of most show visitors 

are solutions that enhance productivity, promote sustainability, 

and improve ergonomics as the workforce of the 

future both ages and shrinks in size. 

“Companies spent the last two years postponing major 

expenditures as they worked to lean everything down in 

order to live to fight another day,” MHIA’s Nofsinger says. 

“Now, attendees are coming to equip and retool existing 

facilities to make them more productive so that as business 

starts to flow they can take advantage of the economic 

recovery.” 

In addition to solidifying purchasing plans as they 

stroll the ProMat show aisles, attendees will discover new 

solutions to streamline operations and improve visibility, 

maximize efficiency and flexibility, cut costs and speed 

time to market. Exhibits from industry, commerce and 

government will be showcased throughout the 300,000 

square foot show floor.

Visit Intelligrated at 

ProMat in booth #2903 and at 

Automate in booth #714. 

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TECHNOLOGY 

Behind Intermec’s acquisition of Vocollect 

WHAT HAPPENS WHEN you combine 

the No. 1 provider of voice recognition 

solutions with the No. 3 provider of automatic 

data capture solutions? That’s 

a question Intermec and Vocollect 

300 Newsome Drive • Yorktown, VA 23692 

Phone: (757) 898-1530 • Fax: (757) 898-1580 

VERTICAL CONVEYING SOLUTIONS 

will begin to answer over the coming 

months and years. Last month, Intermec 

announced that it has entered 

into a definitive agreement to acquire 

Vocollect for $190 million in cash. 

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foot of conveyor for speeds up to 200 

FPM. The total weight capacity in the 

spiral at any one time is 3600 lbs. 

Multiple Entry Spirals The Multiple Entry Spirals allow loads to enter the 

spirals from several different elevations. A new high speed induction conveyor 

provides controlled spiral entry. The conveyor belts are individually adjustable to 

match the spiral pitch. 

Quality and service come first at Ryson. We are the number one spiral 

manufacturer in the USA. For application assistance or more information, give 

us a call or visit www.ryson.com. 

See our Spirals run at ProMat 2011, Booth 1523 

Intermec was No. 3 on Modern’s 

2010 list of the Top 20 suppliers of 

automatic data capture solutions by 

revenue, while Vocollect was No. 14. 

Intermec has not announced its complete 

2010 results just yet, but based 

on estimates, the combined companies 

will have in excess of $795 

million in revenue for 2010—enough 

to give Zebra Technologies a run for 

the No. 2 spot behind Motorola. 

In a press release, Intermec laid 

out some of the rationale for the 

combined companies: 

• The transaction will expand 

Intermec’s product and application 

offerings in the warehouse space. 

• It establishes Intermec as a 

player in the fast growing area of 

voice in industrial applications. 

• Finally, both Intermec and 

Vocollect gain access to expanded 

market channels, customer bases and 

partner networks. 

Earl Thompson, Intermec’s senior 

vice president of mobile business 

solutions, expanded on the release. 

The acquisition, he said, will further 

Intermec’s corporate strategy to be a 

much stronger player in the warehouse. 

He also believes there are real 

opportunities for voice to expand, 

both geographically into new territories 

and markets, and in how the 

technology is applied. 

“Clearly, there’s an adoption 

opportunity for voice in emerging 

markets in Latin America and Asia,” 

he said. “But we also think North 

America is an under-penetrated market. 

Voice is only in 10% to 15% of 

facilities, and it’s mostly focused on 

picking applications. We think voice 

is still an early and disruptive technology 

that can be applied to more 

workflows beyond picking.” 

The acquisition also suggests that 

voice may be ready to evolve from a 

point solution—one that is installed 

by the voice solution provider—to a 

larger, integrated data collection solution 

that integrates with other modes 

of data collection, said David Krebs, 

director of the mobile and wireless 

14 F E B R U A R Y 2 0 1 1 / MODERN MATERIALS HANDLING mmh.com

Voice may be evolving 

from a point solution to 

a larger, integrated data 

collection solution. 

practice at VDC Research: 

“We think there a lot of 

greenfield opportunities 

for voice as we enter this 

emerging wave of multimodal 

applications that 

combine voice with other 

technologies.” 

Krebs added that he will 

be watching to see how 

Intermec’s ADC competitors 

respond. “The acquisition 

strengthens Intermec’s 

warehouse portfolio,” he 

said. “If they can integrate 

Vocollect into their portfolio, 

it will be interesting 

to see how Motorola, LXE 

and Psion respond. They all 

compete indirectly against 

Vocollect and now they’ll be 

competing directly against Intermec as well.” 

For now, Vocollect solutions will be offered by Intermec; 

but, Vocollect will continue to go to market with 

proprietary hardware and software solutions that are 

available to end users that may have someone else’s 

hardware in place for bar code scanning and mobile computing. 

“At this point, there’s no reason to change that 

go-to-market strategy,” said Thompson. 

ECONOMY 

ISM’s January manufacturing 

data shows strong momentum 

to begin 2011 

BUILDING ON THE SUCCESS of a solid 2010, the manufacturing 

sector is off to a promising start in 2011, according 

to the Institute of Supply Management’s January 

Manufacturing Report on Business. 

The ISM reported that the index it uses to measure the 

manufacturing sector—also known as the PMI—was 60.8 

in January, which is 2.3% of December’s 58.5 and marks 

the highest level the PMI has seen since May 2004’s 61.4. 

Any reading 50 or higher represents economic growth, 

and January is the 20th consecutive month economic 

growth has occurred, according to the report. January’s 

strong showing also marks the sixth straight month of 

month-over-month growth in the manufacturing sector, 

according to the ISM. 

“The continuing strong performance is highlighted as 

January is also the sixth consecutive month of monthover-month 

growth in the sector,” said Norbert J. Ore, 

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CPSM, C.P.M., chair of the Institute 

for Supply Management Manufacturing 

Business Survey Committee, 

in a statement. “New orders and 

production continue to be strong, 

and employment rose above 60% for 

the first time since May 2004. Global 

demand is driving commodity prices 

higher, particularly for energy, metals 

and chemicals.” 

In the January report, New Orders 

at 67.8 were up 5.8%, and Production 

at 63.5 was up 0.5%. Employment 

at 61.7 was up 2.8%. Inventories 

were up 0.6% at 52.4, and 

Customers’ Inventories at 45.5 saw 

a 5.5% gain. Backlog of orders was 

up 11.0% at 58.0, and Prices at 81.5 

rose 9.0%. 

Ore told Modern in an interview 

that this report is part of a larger trend 

pointing to positive economic activity 

in the manufacturing sector. He added 

it comes on the heels of a strong 2010, 

when PMI averaged 57.3, marking the 

third highest PMI in the last 20 years 

next to 1994 and 2004. 

“Part of the reason we saw a 

strong January was that the consumer 

showed up for the holiday season, 

“New orders and 

production continue to be 

strong, and employment 

rose above 60% for the first 

time since May 2004.” 

—Norbert Ore, chair of the 

ISM Manufacturing Business 

Survey Committee 

which helped tremendously,” said 

Ore. “The other thing that helped 

was the clarity that was achieved 

over the tax code. People hit January 

with expectations for a good year 

and continuing growth, and the general 

climate was greatly improved.” 

With customers’ inventories up 

5.5%, the report’s respondents 

noted that they felt this number 

remains too low. Ore said the inventory 

issue is one of the more difficult 

things to analyze during this economic 

recovery. 

The reason for this, he said, is 

that there have been several months 

of growth in inventories, but it is 

obvious that manufacturers reduced 

inventory so dramatically that they 

have spent 2010 trying to catch up. 

“I would take the most recent 

reading on customers’ inventories 

to indicate that supply chains are 

getting close to the level that they 

would like to see where they are 

getting more comfortable with their 

inventory level,” said Ore. “I think 

we will also see minor growth in 

inventories on a monthly level going 

forward, with people dropping their 

inventories back to more of a business 

as usual level.” 

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oth above 60, Ore said that the 

strength in manufacturing being carried 

into the first quarter—even if the 

other two months of the first quarter 

are not as strong as January—the 

first quarter and first half of the year 

look to be strong, as opposed to 

previous expectations indicating that 

true growth would not occur until the 

second half of the year.” 

“Our initial expectations are not 

nearly as strong as these numbers 

are,” said Ore. “I think we will see a 

strong first quarter, which could carry 

the first half of the year. We have 

had a lift in confidence, but I think 

there is still a lack of confidence in 

the federal government in dealing 

with deficits. And that could wear 

thin as we get deeper into the year, 

as people could have concerns about 

the ability of the Congress to deal 

with budget issues and could be a 

constraint in the second half of the 

year. But we are off to a very good 

start to the year although it has to 

level off at some point. If we average 

a PMI of 53.5 to 54 for the year, we 

would be very happy.” 

Ore said these positive manufacturing 

cycles generally last from 70 to 

110 months, and there is an expectation 

that with 18 months of manufacturing 

growth in the books, it is 

realistic to expect another 12 at this 

point through the end of 2011. 

blog@way 

Excerpts from executive editor Bob Trebilcock’s blog 

go to... www.mmh.com for complete posts 

Is a hybrid AGV in your future 

If you see hybrid AGV and think of 

the Prius, you’re not alone. A press 

release touting a new hybrid AGV 

had me thinking the same thing. 

However, that’s not what Egemin has 

in mind, according to Dave Noble, 

the AGV-maker’s marketing communications 

director. The hybrid 

AGV Egemin is touting, and will have 

on display at ProMat, is a vehicle 

with dual functionality: an off-theshelf 

man-aboard lift truck that can 

operate manually, like a traditional 

lift truck, or in automatic mode as a 

laser-guided AGV... 

Outrunning the bear or how SAP 

approaches SCE 

You’ve heard the old joke. Two 

hunters are in the woods when they 

startle a big old grizzly bear. As the 

bear starts to charge, one hunter 

says: “I sure hope we can outrun that 

bear.” The other hunter says: “I don’t 

have to outrun the bear. I just have to 

outrun you.” 

That story says a lot about how 

SAP, No. 1 on Modern’s list of the 

Top 20 providers of supply chain 

management software, is approaching 

the supply chain execution 

market today, according to Karen 

Peterson, vice president of supply 

chain execution solution management 

for SAP... 

The next wave of supply chain 

innovation 

Venkat Rajaji has a theory. The next 

big push for technology in the supply 

chain could come about because 

of government regulation. “If you 

look back historically, a number of 

technology changes have been triggered 

by compliance to government 

regulation,” says Rajaji. “Think about 

Y2K. Think about Sarbanes–Oxley” 

Rajaji is global product manager 

for Infor’s product lifecycle management 

division. The government 

regulation he’s eyeing this time is the 

recently passed Food Safety Modernization 

Act... 

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Solutions 

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lift truck TIPS 

Handle with care 

Force control attachments aim to take 

the guesswork out of clamping. 

By Josh Bond, Contributing Editor 

Statistics on the amount of product damaged from lift 

truck attachments and clamps are hard to pinpoint, 

but the tally is undoubtedly in the hundreds of 

thousands of dollars a year, according to Brad Vandehey, 

product manager for attachment manufacturer Cascade 

(www.cascorp.com). 

In recent years, advances in on-board lift truck computing 

and aftermarket attachments have added brains and 

finesse to the brawn of the warehouse workhorse. Still, 

load clamping remains a perennial source of shrinkage. 

Lift trucks have always preferred the blunt technique of a 

spatula over the delicacy of a thumb and forefinger, but 

new force control clamp offerings aim to bestow lift truck 

operators with the precision needed to cut product loss 

and boost productivity. 

The problem is most notable in operations where 

loads of variable weight are handled, according to Vandehey. 

A 2,800-pound pallet might look nearly identical to 

one that weighs closer to 400 pounds, and the operator 

might assume the same clamp force will work for both. 

“If they’re going from a stack of eight washers to a 

single unit, that one washer could be in trouble,” says 

Vandehey. “The operator should not have to guess how 

much force to apply.” 

When working to identify the sources of shrinkage, 

Vandehey is careful to distinguish between poor driver 

habits and the limitations of the machinery. Even if a driver 

has a pretty good idea of how much force to apply, the 

mechanisms for applying that force cannot be accurately 

controlled by the driver. In electric lift trucks, the motor 

spools up at such a speed that it can get away from 

even an experienced driver, Vandehey says. With variable 

clamp force pressure regulators that offer a stick-shift 

interface, operators must learn the gears and use them. 

With force control technology, the operator is taken 

out of the equation. Each load is automatically weighed 

and no more than the needed force is applied. In the near 

future, radio frequency identification tags (RFID) might integrate 

with a warehouse management system to provide 

even more specific information about proper load handling—again 

without any reliance on the operator. 

When force control was implemented at one paper 

facility, the manager informed Vandehey that the difference 

was immediate. 

“After it was installed, he told me, ‘One day the operators 

were crushing rolls, and the next day they were 

not,’” Vandehey recalls. “The plant manager said ‘it was 

intuitively obvious that we are saving money.’” 

At an estimated retrofit cost of $5,000 to $6,000 for 

some models of automatic force control technology, 

Vandehey estimates the savings could be easily recouped 

within a year, and warehouse managers won’t be the only 

ones happy to avoid damaged goods. 

“How hard is it for the average shopper in the 

supermarket to walk past the crumpled paper product 

in favor of the one that looks like it hasn’t been 

crushed?” asks Vandehey. “Hopefully one day that 

won’t be a problem.” M 

Josh Bond is a contributing editor to Modern and can be 

reached at josh.d.bond@gmail.com. 


SUPPLY CHAIN INNOVATION STARTS AT PROMAT ® 2011 

From March 21-24, 2011 the material handling and logistics industry will showcase the latest manufacturing, distribution 

and supply chain solutions at ProMat 2011. 

Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions. Choose from 80 

educational sessions that deliver valuable insights into the latest trends, technologies and innovations. 

ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to 

offer and meet the leading providers face-to-face to help you: 

• Streamline your operations and improve visibility 

• Maximize efficiency and flexibility 

• Cut costs 

• Speed time to market 

• Reduce your carbon footprint 

Register Today For ProMat 2011! 

Find free registration, detailed exhibitor 

information, educational session details, 

show news and your customized My ProMat 

Show Planner at www.ProMatShow.com 

or call 800-446-2622 or 704-676-1186. 

www.ProMatShow.com 

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORK ® 

Find us on: 

Sponsored by: 

Collocated with ProMat 2011

REGISTER TODAY! www.ProMatShow.com 

ProMat 2011 Keynotes 

Monday, March 21 at 8:45-9:45 am 

Fortune Favors the Brave: The Net Gain of Supply Chain 

Security in a Risk-Based World 

Tom Ridge 

First Secretary of Homeland Security 

Terrorism, natural disasters, vendor issues, and geopolitical 

influences can put issues such as supply chain security, 

cross-border collaborations, and security investment 

at the forefront of every proactive business agenda. During 

this keynote, Secretary Ridge will share his views of 

today’s risk-centric environment and how to minimize 

those risks in favor of greater resiliency and security 

across your global supply chain. 

Tuesday, March 22 at 8:45-9:45 am 

The Development of Robonaut 2: 

A Story of Government-Industry 

Collaboration and Technology Transfer 

Learn how NASA and General Motors are working together 

to accelerate development of the next generation of robots 

and related technologies for use in the automotive and 

aerospace industries. This partnership led to development 

of Robonaut 2 (R2), a state-of-the-art dexterous humanoid 

robot built and designed at NASA Johnson Space Center. 

ProMat 2011 Educational Tracks 

Tuesday, March 22 at 1:00-4:15 pm 

The people side of the supply chain 

This full afternoon track takes a close look at how you 

can be successful at leading the people who keep your 

supply chain moving. Learn how to keep your workforce 

interested, engaged and committed to a supply chain 

career and to your company. 

Topics include: 

My aspirations: 20-somethings 

sound off on what makes them tick 

Kim Absil, Sears Holdings 

Josh Dennie, Optimax 

Justin Love, Schlumberger 

Craig Eckrenrode, Stevens Co. Inc. 

What are you worth and why? 

Mitch Mac Donald, DC Velocity 

Dave Blanchard, Material Handling & Logistics 

Keeping top talent as the economy recovers 

Dan Boos, Boos Consulting Services 

Wednesday, March 23 at 1:00-5:00 pm 

Sustainability, the supply chain and their future together 

In this full afternoon session, a wide range of speakers 

will detail how to get started, what works today, and 

what a sustainable supply chain will look like in a 

ouple of decades. 

Topics include: 

The green supply chain starts at 

home Steve Thomas, Emmy-award 

winning television host of “This Old 

House” and “Renovation Nation” 

Top trends in industrial sustainability 

Gary Forger, Material Handling Industry of America 

How LEED certification cuts costs and improves efficiencies 

Michael G. Englehard, ProLogis 

Walmart’s plan for sustainable distribution 

Virginia Garbutt, Walmart Canada 

A look at the sustainable supply chain of 2030 

Benoit Montreuil, Université Laval 

What you can do to green the supply chain 

Steve Thomas 

Steve Thomas 

How to capitalize on 

diversity in the workforce 

Dan Boos, Boos Consulting Services 

Preparing people for the workforce 

Dan Boos 

Kimberly Ellis, Virginia Tech 

Justin Love, Schlumberger 

Kathy DePiro, Greater Altoona Career & Tech Center 

Craig Eckenrode, Stevens Co. Inc. 

What a peer learning group can do for your career 

Josh Dennie, Optimax 

Bruce Peters, WCEOHQ Radio 

Register Today For ProMat 2011! 

Find free registration, detailed exhibitor information, 

educational session details, show news and your 

customized My ProMat Show Planner at 

www.ProMatShow.com or call 800-446-2622 

or 704-676-1186. 

www.ProMatShow.com

SHOW PREVIEW 

Chicago 

March 21-24, 2011 

PUTTING 

PRODUCTIVITY 

TO WORK 


Scalable staging buffer for goods-to-person picking operations 

Generating up to seven times greater throughput in a smaller footprint than conventional 

storage systems, the Multishuttle staging buffer feeds workstations at high rates to keep 

workers fully utilized. The system is ideal for applications that require dynamic product 

sequencing to support goods-to-person order fulfillment, pick face replenishment, palletizing, 

and production buffers. Included are multiple levels of rack structure, carrier vehicles, 

conveyor and software. Each level of the rack structure includes input/output conveyor and 

a carrier vehicle that travels horizontally to access loads stored in the rack structure (typically 

totes or trays). An extraction device on each carrier vehicle accesses the loads in the rack. The 

system may be configured in a variety of layouts, including overhead spaces and under/over 

obstructions for the best cube utilization. Dematic, 800-457-9783, www.dematic.us. Booth 

3603 and 3612. 

Voice-directed software with 

graphical management 

The latest version of Jennifer VoicePlus software 

for voice-directed warehouse operations has 

been released. Included is the Engage management 

services console, an Internet application 

that provides a suite of graphical management 

tools to analyze and manage voice operations. 

Also offered is Mobile Engage, a smartphone/ 

PDA-based application providing the same management 

capabilities for mobile devices. This 

functionality enables managers to be on the 

warehouse floor without losing touch with critical 

operational information. The systems are ideal 

for use in grocery and foodservice, retail, medical 

products, industrial supply, and consumer product 

goods distribution. Lucas Systems, 724-940- 

7000, www.lucasware.com. Booth 3879. 

Tilt-tray, cross-belt 

sorters offered 

The IntelliSort CB cross-belt and 

TT tilt-tray sorters for high-volume 

distribution centers, parcel hubs 

and fulfillment operations reliably 

handle sortation in high-capacity, 

high-speed sorting environments. 

Both cross-belt and tilt-tray technologies 

are ideal for use in applications 

with a variety of product 

sizes and shapes that require high 

throughput and accurate sortation. 

Compact and modular, the sorters 

may be used in new construction or retrofit applications. Intelligrated, 

866-936-7300, www.intelligrated.com. Booth 2903. 

ProMat 2011, slated for March 

21-24, will showcase more 

than 700 exhibits and include 

a comphrehensive educational 

conference. The event, to be held 

at McCormick Place in Chicago, 

will offer an array of products to 

help improve productivity at your 

company. 

Show hours 

Monday 10:00 a.m. - 5:00 p.m. 

Tuesday 10:00 a.m. - 5:00 p.m. 

Wednesday 10:00 a.m. - 5:00 p.m. 

Thursday 10:00 a.m. - 3:00 p.m. 

AGV converts to operator-guided forklift 

Morphing manual and automatic operations, a new hybrid 

automated guided vehicle allows an operator to interrupt 

automatic AGV operations, move product manually and then 

place the forklift back into fully automatic laser guidance 

mode. The vehicles are offered in two sizes—3,500- and 

5,500-pound capacities—with lifting heights up to 23 feet. 

Typically interfacing with deep lane floor stacking, pushback 

rack, drive-in rack and standard racking, the vehicle features 

industrial lead-acid 

batteries, laser guidance 

and navigation, 

advanced laser safety 

systems, graphical 

touchscreen monitor, 

Windows OS and wireless 

communications. 

Options include RFID 

readers, bar code scanners, 

3D camera technology, 

robotic battery 

exchange, automatic 

battery charging, mechanism 

side-shift and single/double 

fork systems. 

Egemin, 616-393-0101, 

www.egeminusa.com. 

Booth 2347. 


SHOW PREVIEW 

Robotic imaging, picking cell 

The Robo-Pick fully automatic picking cell compiles 

shipments from two to 20 articles in the correct 

quantity from a range of 5,000 to 50,000 articles 

in stock. The system combines 3D and 2D picture 

processing to identify products on a passing tray. 

Products in several layers or inclined position, jetblack 

articles, round products or asymmetric or 

beveled packages do not affect the vision system. 

Individual products do not need to be programmed 

into the system, which uses already existing allocations 

of transport units and SKUs in automated 

warehouses to ensure that the customer receives the 

correct articles. Schaefer Systems, 800-876-6000, 

www.ssi.schaefer-us.com. Booth 2303. 

Reinforced construction enhances 

vertical carousel’s reliability 

Engineered for enhanced reliability and uptime, the 

Avenger vertical carousel uses a patent-pending 

forging to reduce stress on structure components, 

plus double-reinforced arm assembly to provide 

extra strength and durability. Each carrier (shelf) has 

eight scissor arms to eliminate bending, tearing and 

breaking. A forging and roller attaches the arms to 

the track, instead of 

traditional pin and roller 

assembly, to reduce 

stress and prevent system 

failure and machine 

damage. The carousel 

is offered in multiple 

models for light- to 

heavy-weight applications, 

with warranties 

up to 10 years on 

some models. Sapient 

Automation, 800-639- 

5805 www.GetSapient. 

com/Avenger. Booth 

4231. 

AS/RS single-mast crane 

lifts 220 pounds to 39 feet 

The Mustang Evo automated storage and 

retrieval system for mini-load use is a singlemast 

crane with a maximum payload of 220 

pounds and an optimum height of 39 feet. 

Features include lightweight construction 

based on aircraft concepts to reduce overall 

weight by 25% with a lighter mast with specially 

rolled profiles, consistently adapted 

material thickness and high-strength bolted 

connections for increased stiffness. Further 

enhancements include improvements to the 

crane’s center of gravity, better distribution 

of loads to the running wheels, and the 

elimination of drive motors at the top of the 

machine for a reduction in maintenance and operational costs. 

TGW-Ermanco, 231-798-4547, www.tgw-ermanco.com. 

Booth 612. 

Flexible WMS easy to install 

To meet the logistics needs of any size warehouse, the EasyWMS 

warehouse management system is simple to install and requires 

minimal implementation time. Flexible enough to be used in facilities 

with varying levels of complexity, the WMS supports operating systems 

up to Windows 

7. Multi-lingual 

technical support 

is offered. Features 

include the display 

of real-time statuses 

of stock levels, locations, 

productivity 

and shipments for 

increased warehouse performance, increased turnover ratios, optimized 

order preparation, improved online inventories, and reduced 

time needed for stock management. Interlake Mecalux, 877-632- 

2589, www.interlakemecalux.com. Booth 2012. 

Smart AGVs can 

be used in moving 

assembly lines 

SmartCart AGCs are flexible, 

low-cost automatic guided vehicles 

that can be used in assembly 

lines, to deliver pallets to 

and from stretch wrappers, 

roller conveyors and palletizers, 

or to move loads around 

a facility. The carts are guided 

by updated, easy-to-use software that accepts user-authored 

system changes and enables troubleshooting without outside 

assistance. For implementation in a continuous moving assembly 

line, an unlimited number of carts can be synchronized at a close 

distance, while traveling as slow as 6 feet per minute. Jervis B. 

Webb, 800-791-3092, www.jervisbwebb.com. Booth 2003. 

24 F e b r u a r y 2 0 1 1 / Modern Materials Handling mmh.com

Laser bar code scanner debuts 

Offering enhanced coverage, ease of use and flexible connectivity 

options, the AccuLazr AL5010 laser bar code scanner uses modular 

components including scan head, mounting base, power supply and 

choice of interface modules. The unit is ideal for applications including 

pick modules, print and apply, routing, and sortation. Housed in a 

rugged IP65 enclosure, the scanner comes in five models and covers 

distances from 5 to 48 inches. Standard and high-density configurations 

are supported. Depending on the model, the device includes 

Ethernet-Ethernet/IP, RS232/422 serial ports, tach input and optional 

I/O modules with DeviceNet/Profibus plug-ins. Accu-Sort, 800-227- 

2633, www.accusort.com. Booth 2047. 

Counterbalanced AGV for warehousing 

Developed for automation of pallet movement in warehouses, 

the counterbalanced automatic guided vehicle 

can pick up loads from the floor and block stack or interface 

with conveyors, stands and racking (standard single 

deep, pushback, flow through and drive-in). The warehousing 

AGV uses flexible laser guidance and can use 

secondary guidance technology if required to navigate 

in narrow aisles and racking. The vehicle has a maximum 

capacity of 5,000 pounds and can be configured to handle 

single or double pallets. JBT, 215-822-4600, www. 

jbtc-agv.com. Booth 3915. 

Stand-up counterbalanced lift truck 

The models 4150 and 4250 stand-up counterbalanced lift trucks handle 

load capacities from 3,000 to 5,000 pounds. For a smoother ride, 

the suspension adapts automatically to each operator’s weight while 

a cushioned floor mat isolates the driver from impact and vibration. 

Capable of performing right-angle stacking maneuvers in less total 

area, the three-wheel vehicles include a dual steer wheel, allowing 

one wheel to counter-rotate during turns for a shorter turn radius with 

reduced tire loading and steering friction. Visibility is enhanced with 

an angled front cover for a clear view of forks as they engage loads 

on the floor for more accurate handling and stacking. The Raymond 

Corp., 800-235-7200, www.raymondcorp.com. Booth 3219. 

Move workers, 

loads with 

mezzanine 

platform lift 

Traveling from 8 to 

18 feet, a line of rider 

mezzanine lifts is 

offered. Ideal for moving 

workers with loads 

up one to two floors— 

or to high stages and 

mezzanines—the units 

include platforms ranging 

in size from 6 x 8 to 

8 x 12 feet. Advance 

Lifts, 800-843-3625, 

www.advancelifts. 

com. Booth 2059. 

WMS tool for reconciliation of test and production data 

For easier reconciliation of test and production environments in multiple sites, the environment 

manager tool has been added to the supplier’s 2010.2 warehouse management software 

release. The new tool propagates data between warehouse instances while checking for data 

differences without requiring duplicate configurations. By generating templates based on static 

information like locations and item definitions, the module reduces the time needed to go 

live with new warehouses or bring up new clients within those warehouses. Because it can be 

configured to ensure the user assembling the data cannot be the same user that propagates it 

to another system, the tool supports Sarbanes-Oxley compliance. RedPrairie, 877-733-7724, 

www.redprairie.com. Booth 3676. 

Independent transport robot, gantry case/layer robot featured 

Capable of independently performing random origin to random destination transport, the ADAM 

intelligent mobile robot is ideal for moving work-in-process materials and finished goods in lean 

manufacturing and assembly applications. Missions are completed autonomously, navigating 

around fixed and moving objects, without guide wires, reflectors or transponders. A new gantry 

robot based case and layer picking solution for automated operation in food, beverage and 

consumer products distribution facilities is also offered. This flexible, integrated system delivers 

cases exactly the desired sequence for automated mixed case palletizing or direct trailer loading 

at the dock. RMT Robotics, 905-643-9700, www.rmtrobotics.com. Booth 3503 and 3821. 


SHOW PREVIEW 

Plastic holders for slotted 

bins protect labels 

Tri-Dex label holders for standard plastic 

bin label slots are made of clear PVC. 

Fabricated in a tri-fold configuration, the 

holders seal 

and protect 

the label. 

Printed labels 

slide into 

the holder 

and snap in 

place without 

adhesive backing. The holders are 

offered five popular sizes to retrofit most 

standard bins. Laser inserts are included 

with printing instructions. A single package 

includes 25 holders. Aigner Index, 

800-242-3919, www.aignerindex.com. 

Booth 1914. 

Expanded pallet jack line 

A new line of pallet jacks ranges in capacity 

from 2,200 to 10,000 pounds, with 

widths from 16 to 43 inches, and fork 

lengths from 23 to 96 inches. Where 

required in pharmaceutical, food or other 

applications, galvanized and stainless 

steel jacks are available. Also included 

in the line are straddle, high-rise scissor, 

low profile and weigh scale jacks. The 

trucks feature fully serviceable pumps, 

heavy-duty steel frames and fully adjustable 

push rods. Options include automotive 

brake attachments, load backrests 

and a choice of wheel configurations and 

materials. Clark Material Handling, 866- 

252-5275, www.clarkmhc.com. Booth 

2019. 

Ergonomic workbenches, 

customizable 

A line of ergonomic modular workbenches 

and related products and accessories 

can be customized for specific 

needs, including enhanced production 

and a reduction in repetitive motion. 

The complete product line includes basic 

workbenches, packaging and mailroom 

workbenches, computer stations and 

work surfaces. For further configuration 

to meet unique application requirements, 

accessories include adjustable 

metal shelves, footrests, louvered panels, 

modular drawer systems, pull-out 

keyboard rests, tool balancers as well as 

torque arms. Pro-Line, 800-739-9067, 

www.1proline.com. Booth 305. 

Mini-load AS/RS includes 

two stacker cranes per level 

The Duosys mini-load automated storage 

and retrieval system includes tuning control 

technology. This design ensures that 

its two storage/retrieval machine stacker 

cranes can function in the same aisle 

without interference. The units move past 

each other to perform storage and retrieval 

operations. The system can be laid out 

in two levels so that four SRMs operate 

simultaneously on the same rack, producing 

throughput of up to 2,200 cases per 

hour. Daifuku America, 866-414-2057, 

www.daifukuamerica.com. Booth 2003. 

Give Your Heavy Pallets the Slip. 

Material Handling 

Ship more product per load with Rehrig’s weight, space and cost saving Slip Sheets. 

Come see us 

at ProMat 

Booth #3526 

Rehrig co-extruded Slip Sheets are a cost-effective alternative 

to pallets. Impervious to moisture, high tensile strength plastic 

provides added tear resistance making them the perfect 

replacement for fiber or corrugated sheets, as well. 

Available in standard or custom sizes, Rehrig Slip Sheets provide 

superior slide resistance, keeping goods securely in place. Manufactured 

from nearly 100% recycled material, each sheet is also 100% recyclable. 

Beyond the sale, Rehrig can help you develop a customized re-use or 

buy-back program, further lowering your average cost per trip. 

©2011 Rehrig Pacific Company 

Phone: (800) 546-4993 

Email: info@rehrigpacific.com 

Web: www.rehrigpacific.com 

Call us for more information about: 

Tier sheets, Liner sheets, Layer sheets, 

Cap sheets, Divider sheets, Pallet pads 

and Separator sheets 

A fAmily trAdition of growth, service And innovAtion 


Two-toned bins for effective 

inventory control 

Offered as a low-cost alternative to highend 

inventory control systems, a line of 

indicator bins 

includes two 

colors in one 

unit. Formed 

with a bi-color 

mold to achieve 

a two-toned 

bin, the units 

simplify visual 

recognition when supplies need to be 

replenished. They are stocked with a 

divider in place to designate volume 

for inventory reserve, and picked from 

the blue side until reaching the divider. 

The bins are then flipped to the orange 

reserve side to visually indicate low inventory 

levels and the need for replenishment. 

Akro-Mils, 800-253-2467, www. 

akro-mils.com. Booth 1219. 

Image-based 

bar code reader 

The DataMan 500 image-based bar code 

reader uses custom software to achieve 

higher read rates by processing the 1D 

bar codes that laser readers cannot read, 

including damaged, distorted, blurred, 

scratched, low height and low contrast 

codes. It 

captures 

images at 

up to 1,000 

frames per 

second and 

is capable 

of reading 

codes in any 

orientation. 

The reader allows users to see what the 

reader sees on a monitor or through 

image archiving for later review. Cognex, 

508-650-3000, www.cognex.com. 

Booth 768. 

Collapsible plastic container 

Offered in two sizes—48 x 45 x 26.5 and 

48 x 45 x 34 inches—BV4845 BulkPak 

containers stack securely when full and 

collapse when empty for reduced transportation 

costs and condensed storage. 

The reusable containers fit 84 filled bins 

per inbound truckload and 252 collapsed 

bins per return truckload. Features 

include improved shipping density with 

a higher fill line that allows for more 

product per bin, a replaceable bottom 

stringer that reduces replacement cost 

of full base, and optimized spring-loaded 

latches. Orbis, 888-307-2185, www. 

orbiscorporation.com. Booth 1803. 

Forklift fuel cells, hydrogen 

refueling products 

The PowerEdge hybrid fuel cell system 

replaces standard lead acid batteries 

in electric lift trucks, and the PowerTap 

hydrogen generator 

and refueling station 

provides a low-emission, 

cost-effective 

source of fuel from 

natural gas. Delivering 

quick refueling in 

less than 2 minutes, 

the systems produce 

consistent voltage 

throughout a shift, generating 

up to 10% gains 

in productivity. Nuvera 

Fuel Cells, 617-245- 

7500, www.nuvera. 


Repair damaged rack legs 

For rack repair, the high strength Elite 

vertical leg kit is offered. The patented 

system is engineer-certified to guarantee 

high resistance to future impacts. Fully 

bolted, the engineered system anchors 

to concrete flooring with three 0.75-inch 

anchors. Mac Rak, 815-723-7400, www. 

macrak.com. Booth 1277. 

3-D Visualization 

WMS Demo @ 

ProMat 2011 

Booth # 3926 

Automated Storage & 

Retrieval Systems (AS/RS) 

Savanna.NET® Warehouse 

Management Software (WMS) 

Need to DOUBLE Storage capacity? 

Westfalia’s AS/RS can fit into 

existing buildings only 20’ high 

Need to PICK Faster? 

Westfalia’s Savanna.NET® WMS 

provides fast, efficient, & accurate order 

picking at an affordable price 

Westfalia Technologies, Inc. 

717-764-1115 • 800-673-2522 

www.WestfaliaUSA.com 

OUR INNOVATION 

YOUR SOLUTION 


SHOW PREVIEW 

Fast battery charging from 

high frequency system 

Using high frequency technology, eMax 

HF fast charger provides high charger 

efficiencies at lower operational costs, 

with high power factors to reduce AC 

line draws and minimize 

infrastructure 

investment. Compact, 

the charger’s small 

footprint frees up 

floorspace. It is always 

connected and fully 

networked, with a wireless 

communications 

interface for real-time 

battery and charger fleet management. 

EnerSys, 800-538-3627, www.enersys. 


Fit 315 collapsed containers 

into trailer 

Ideal for applications including manufacturing, 

plastic packaging products, food 

processing, dry goods and lightweight 

plastic components, the Maximizer reusable, 

collapsible plastic container holds 

up to 1,000 pounds. It features a 48 x 

40 x 41 inch footprint, and folds to allow 

eight collapsed boxes to occupy the area 

of one assembled unit for a return ratio 

of 315 folded containers in a 53-foot 

trailer. The container can be set up or 

folded down in minutes and weighs 30% 

less than other plastic reusable alternatives. 

Buckhorn, 800-543-4454, www. 

buckhorninc.com. Booth 1219. 

Control, monitor 

overhead cranes 

The LRC- M1 wireless control system for 

electrical overhead traveling cranes can 

control up to four motions with two ergonomic, 

multi-axis joystick controllers. The 

trolley/hoist selector, two auxiliary push 

buttons and toggles are mounted on an 

impact-resistant housing. The system is 

enhanced by enterprise software to communicate 

wirelessly and bi-directionally 

with all fixed or mobile assets on a near 

real-time basis using either the IP-based 

cellular networks, 802.11, or both. 

Cattron Group, 724-962-3571, www. 

cattrongroup.com. Booth 1859. 

Palletizer redesigned for 

better ergonomics 

For enhanced ergonomics, the PalletPal 

level loader has been redesigned with 

a new, smaller base that permits the 

operator to step closer to the platform 

for faster, safer and easier loading and 

unloading of pallets. Heavy-duty springs 

automatically 

lower or raise 

a pallet load 

(from 400 to 

4,500 pounds) 

as weight 

is added or 

removed, 

maintaining 

the top layer 

of stacked 

containers at 

a convenient height. A turntable ring, or 

optional turntable platform, at the top 

of the equipment allows the load to spin 

so the operator remains in the same spot 

throughout the loading or unloading 

process. Operating without power and 

maintenance free, the unit includes fork 

pockets at the base for easy relocation. 

Southworth, 207-878-0700, www.southworthproducts.com. 

Booth 403. 

Aigner. Look to the Leader in Label Holders. 

Aigner has the solution for most every 

labeling need: Famed Hol•Dex ® on 

shelves, bins, drawers. Hi-Lo on 

shelving above or below sight-lines. 

Wire•Rac on wire shelving. 

Magnetic Cardholders for instant 

adhesion on metal. SuperScan for 

scanable display on pallet racks. 

Open•Edge for easy label 

insertion on industrial shelving. 

Write-On magnetic tags for 

use with wet-erase markers. These 

quality products assure you easy-read 

identity with long-life durability. All 

paper inserts are now laser ink-jet 

compatible. Call for our 

catalog 

and nearest dealer. 

AIGNER 

INDEX 

FREE 

Samples! 

Aigner Index Inc. 

218 MacArthur Avenue 

New Windsor, NY 12553 

Tel:1.800.242.3919 

Email: info@aignerindex.com 

Fax: 845.562.2638 

www.aignerindex.com 

Write-On 

SuperScan 

Open•Edge 

Wire•Rac 

Magnetic 

Cardholders 

Hi-Lo 

Hol•Dex

Industrial fan delivers 

energy savings 

The durable and adaptable 8- to 24-foot 

diameter PowerfoilX industrial fan generates 

maximum airflow. Engineered and 

machined from materials that promote 

year-round energy savings, the fan 

includes the supplier’s NitroSeal Drive 

custom gearbox. It is backed by a 10-year 

warranty with factory installation. Big Ass 

Fans, 877-244-3267, www.bigassfans. 


New version of WMS 

features visualization 

Version 2.3 of Savanna.NET warehouse 

management software has been launched. 

New features include real-time 3D visualization 

of the warehouse, a dashboard 

for tracking key operations statistics, 

streamlined user rights management, 

and improvements to the order picking 

module for integrating third-party picking 

solutions. The Web-based system’s visualization 

functionality has been developed 

with gaming software and allows a view 

of the facility from any angle. Individual 

items/SKUs can be identified and filtered, 

as can warehouse zones. Westfalia 

Technologies, 800-673-2522, www. 

WestfaliaUSA.com. Booth 3926. 

Electric counterbalanced 

sit-down lift trucks 

Eight models of the RX60 series of 80-volt 

electric counterbalanced sit-down lift 

trucks are offered. Capacities range from 

5,000 to 10,000 pounds. Enhancements 

include an improved rail that strengthens 

the mast and limits deflection, 

travel speeds of 12 miles per hour, and 

lift speeds of 100 feet per minute. The 

vehicles include a heavy-duty cast ductile 

iron steering axle, major electrical component 

placement inside the counterweight, 

and thermal protectors. Linde Material 

Handling-North America, 843-875-8319, 

www.lmh-na.com. Booth 641. 

Handheld features open 

platform software 

The Omnii modular mobile computing 

platform allows the supplier, 

its resellers and developer 

partners to co-create adaptable 

solutions through an open, online 

community. By being almost 

completely re-configurable in 

the field, devices built on the 

platform can be adapted for new 

technologies or be re-purposed as needs 

change. The XT10 device uses this platform 

and is IP65 rated. Features include 

a 6.5 foot drop rating, Texas Instruments 

OMAP3 processor, and extended battery 

life. Psion, 800-322-3437, www.psion. 


Handle longer loads with 

single-beam gantry crane 

A new line of single-beam, rubber-tired 

gantry cranes—the SB Series—is offered 

in 15-, 30- and 70-ton models. The cranes 

are ideal for handling longer loads and 

tandem picks, replacing a single 100-ton 

gantry with spreader bar. The weight 

of the load located directly below the 

frame. Shuttlelift, 920-743-8650, www. 

shuttlelift.com. Booth 1176.

SHOW PREVIEW 

nufacturer 

nd time 

Load transfer station 

handles 2 loads per minute 

A fully automatic load transfer station 

transfers up to two full loads per minute. 

Using a pallet stacker, pallet dispenser, 

input conveyor and an output conveyor, 

the station receives loads from a conveyor, 

transfers the load from one load base 

STORAGE/STAGING 

the 

to another, 

conceptual 

stacks 

design. 

the pallet 

System 

and automatically 

flexibility discharges for the future transferred expansion. load The end result 

designers built in additional 

saved onto a 19% conveyor. of the Transferred available loads space can and more than half the 

cost 

then 

and 

be stored 

weight. 

in a high rise automated 

storage and retrieval system, picked up 

downstream by a lift truck, or travel to 

another operation. Columbia Machine, 

800-628-4065, www.loadtransfer.net. 

Flexcon 

908-871-7000 

www.flexcontainer.com 

Booth 972. 

Standard and custom 

containers 

A comprehensive line of plastic containers, 

bulk boxes, carousel containers, and 

vertical lift dividers are offered in more 

than 3,000 standard sizes and any custom 

size. Highlighted are a new line of 

insulated shippers, vertical lift dividers 

and custom case samples. Custom units 

are created to meet unique specifications 

and requirements. Flexcon Container, 

908-871-7000, www.flexcontainer.com. 

Booth 1726. 

Steel lockers 

Valor lockers are constructed of prime, 

high-grade steel and feature a 14-gauge 

door, 16-gauge sides, top and bottom, 

and a 18-gauge back. An electrical cutout 

in the rear top corner offers access to an 

electrical feed for charging laptops, cell 

phones and other devices. To keep garments 

cool and dry, the locker features 

maximum ventilation openings. Lyon 

Workspace, 800-323-0082, www.lyonworkspace.com. 

Booth 659. 

Warehouse management 

and control system 

A turnkey solution for warehouse control 

and automation, supply chain labor, 

and warehouse information management 

is offered through a partnership 

between the supplier and Softeon. The 

system improves order picking and inventory 

management, while reducing labor 

through automated pick, pack and ship 

technologies. The system is ideal for each 

picking and mixed SKU item/case/pallet 

picking and shipping. Numina Group, 

630-343-2604, www.numinagroup.com. 

Booth 4234. 

r 

lled 

, the 

fits. 

heir 

uch, 

uct 

ith 

rent 

d to 

eds. 

facin 

er’s 

“We 

kits 

ght 

tion 

s of 

Get the bench you need 

and get it fast. 

Your work can’t wait. With Pro-Line’s “In Stock” Program, you 

can get the exact modular workbench your application demands 

in 5 days or less - with your choice of work surface, color, and 

many accessories and options. 

• For decades, Pro-Line workbenches have been synonymous 

with quality, functionality and unmatched ergonomic design. 

• Choose from the manual height adjust Ergo-Line, Millennium 

II electric height 

adjusting workbench, 

the popular Model 

HD, Dimension Next 

Modular Workstations, 

and more. 

• Configure your 

workstation with the 

exact accessories 

you need. 

www.industrialworkbenches.com 

1proline.com 

(800) 739-9067 

Pro-Line is a division of the 

R.W. Hatfield Co., Inc. 

RIDER 

MEZZANINE 

LIFTS 

Rider mezzanine lifts are 

designed to move large 

loads, and their operator 

between floors or up 

to mezzanines. 

These lifts will travel 

from 8 feet to 18 feet 

and have platform sizes 

ranging from 6Õ x 8Õ 

up to 8Õ x 12Õ. 

1-800-843-3625 

www.advancelifts.com 

30 F e b r u a r y 2 0 1 1 / Modern Materials Handling mmh.com 

Modern Materials Handling / October 2009 27

Increase conveyor speed 

with replacement spools 

For quick replacement of standard lineshaft 

conveyor spools, the split-speedupspool 

does not require disassembly of 

the conveyor to replace spools and spacer 

tubes. The spools increase conveyor 

speeds by up to 44% while reducing 

noise. Capable of fitting both 1-inch and 

25-millimeter line-shafts, the spools feature 

alignment notches on one side for 

fast installation by feel behind frames or 

guards, and in lit or dark areas. Colored 

bright green for safety, the spools visually 

indicate which conveyor zones are 

moving faster. Dura-Belt, 800-770-2358, 

www.durabelt.com. Booth 352. 

Sort high densities 

at high speeds 

Offered with multiple tray configurations 

to allow for maximum throughput 

capacity and gentle product handling, 

high speed unit sorters improve accuracy, 

productivity and efficiency. The simple 

and flexible sorters handle high densities 

at quiet decibels. They are ideal for sorting 

pharmaceuticals, books, multimedia, 

small packages, flats, shoes, jewelry, 

office supplies, e-commerce items, optical 

products, apparel and accessories. To 

suit specific application needs, various 

induction methods and sorting destination 

types may be specified. EuroSort, 

410-363-6345 www.eurosort.com. 

Booth 2619A. 

Environmentally friendly 

suspension packaging 

Ideal for low-profile, small electronics, 

the Korrvu Hybrid packaging creates 

retention-type surface protection with 

a suspension-type hold. The system 

uses a proprietary retention frame and 

elastomeric film. When the side flaps 

of the corrugated frame are folded up, 

the attached film is loosened, creating 

an insertion pocket where the item is 

placed. When the flaps are folded down, 

the film stretches 

over the product 

to hold it 

securely in place. 

Sealed Air, 800- 

648-9093, www. 

sealedair.com. 

Booth 3919. 

Pick-to-light for kitting, 

picking processes 

Intended for error-proof use in parts picking, 

kitting, assembly and sequencing, the 

Build2Light is a complete light-directed 

picking system. The system is engineered 

for production environments, with low 

cost of entry and scalability, making it ideal 

for pilot programs. All key hardware is 

included, enabling operator self-sufficiency, 

fast installation, and stand-alone function 

without the need to interface with larger 

host manufacturing applications. Lightning 

Pick Technologies, 262-250-2143, www. 

build2light.com, www.lightningpick.com. 

Booth 4250. 

New module for RFIDenabled 

load tracking system 

The new Orchestrator work queue and task 

management module has been added to the 

VisiblEdge RFID-enabled system that automates 

data capture for location and identification 

of lift trucks and their loads. By leveraging 

automated load and location data capture 

capabilities, the module improves the forklift 

operator’s experience. It also integrates with 

a facility’s WMS or ERP to streamline the distribution 

and execution of material movement 

work instructions. Rush Tracking Systems, 

913-227-0922, www.rushtrackingsystems. 


 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


SHOW PREVIEW 

Intelligent jib moves 

with operator 

Offered as an easier-to-move alternative 

to the traditional workstation jib/ 

chain hoist combo, the G-Jib includes 

the G-Force intelligent lifting device in 

conjunction with a workstation jib crane. 

The actuator of the lifting device stays in a 

fixed position near the vertical truss of the 

crane, eliminating the dead weight that 

comes with moving a hoist along the rail. 

The system travels with the motion of the 

operator and is offered in two capacities: 

330 and 660 pounds. Gorbel, 800-821- 

0086, www.gorbel.com. Booth 3623. 

Inventory management 

and control software 

FastPic5 inventory management and 

control software now provides a batch 

handling function to improve throughput 

and productivity. The software employs 

three methods: static batching creates 

batches ahead of time at the order entry 

department; dynamic batching builds the 

next batch for the operator to reduce 

workload; and operator-defined batching 

allows the picker to create the next batch 

from a list of pending orders. The system 

integrates with host software, pick and 

put-to-light technology and automated 

storage and retrieval systems to increase 

throughput up to 600% and accuracy rates 

up to 99.9%. FastPic, 207-854-8663, 

www.fastpicsystems.com. Booth 2919. 

Live roller conveyor 

replacement belts 

The economically priced TF-100T live 

roller conveyor belt is offered. Capable 

of navigating small conveyor pulleys, the 

belt cuts replacement costs. If needed, the 

unit can be spliced directly into the existing 

belt. Habasit America, 678-288-3600, 

www.habasitamerica.com. Booth 1044. 

Workstation includes 

on-board power 

To run a computer, printer and other 

devices simultaneously, the PC series 

mobile powered workstation incorporates 

on-board 

power, along with 

ample shelf space for 

products and other 

items. When charged, 

the cordless battery 

offers integrated, 

seamless power for up to 12 hours of 

normal use. Six-inch swivel casters lock 

for stability once the portable station is 

positioned. Carts come in dimensions 

up to 24 x 48 x 37 inches with five different 

battery/inverter/charger packages. 

Newcastle Systems, 781-935-3450, 

www.newcastlesys.com. Booth 4768. 

Easily identify inventory 

with clear view storage bins 

For inventory organization, clear-view 

ultra stack and hang bins are made 

of injection-molded polypropylene. 

Front, back and side grips provide easy 

handling, while a built-in, rear hanger 

suspends the bins from louvered panels 

or rails. Resistant to rust and corrosion, 


the bins are waterproof. Dividers maximize flexibility and keep 

contents organized. Twenty different models are offered, in sizes 

ranging from 5 x 4.125 x 3 to 17.125 x 14.75 x 10.25 inches and 

capacities from 8 to 75 pounds. Quantum Storage Systems, 

800-685-4665, www.quantumstorage.com. Booth 1922. 

Print, apply 

shipping label and 

packing slip 

For distribution and fulfillment 

centers, the TwinPrint 

system includes printers 

and printer applicators with 

two printheads that print 

both the shipping information 

and a confidential 

packing slip on a single label. Once applied to the carton, the 

packing slip is accessed by tearing a zipper strip. The information 

on the printed liner remains confidential and provides 

tamper-evident protection during shipping. By repurposing the 

label liner as the packing slip, the system eliminates a traditional 

packing slip and plastic envelope from the waste stream. FOX 

IV Technologies, 877-436-2434, www.foxiv.com. Booth 4103. 

Customize WMS with 

applications from app store 

Offered as an “app store” for the supplier’s warehouse management 

system, the App Station is a collection of workflows 

that can be browsed and added to the WMS at any time. All 

apps are free and user-installed to add functionality without 

custom-coding. The system includes access to new supply chain 

software innovations, and the ability to pick and choose only 

the functionality needed for the WMS without affecting current 

customizations. HighJump Software, 800-328-3271, www. 

highjump.com. Booth 4572. 

VLM offers Web-based 

inventory management 

Intended for discrete part storage and 

retrieval, the PowerColumn3 vertical lift 

module incorporates automated height 

sensing for slotting flexibility by tray 

height. Five tray widths, four depths, two 

tray-carrying capacities (1,000 and 2,000 

pounds), and 11 configurations are included 

standard. Heights range from 10 to 50 

feet, and custom models may be specified. 

The VLM incorporates intelligent inventory 

management and control in a software as a service format, 

allowing the linkage of multiple machines in different locations 

together through Web-based software. SencorpWhite, 800-275- 

1442, www.sencorpwhite.com. Booth 4407. 

Repair floor cracks with deflection device 

The Joint-Saver can be used to repair loose, rocking, spalled 

joints and cracks in flooring that can damage materials handling 

equipment and cause injury and tipped loads. The cost-effective 

repair device is offered in three sizes to accommodate a range 

of floor thicknesses in ambient and cold temperature environments. 

The units eliminate damaging deflection and permanently 

restore smooth, positive load transfer at all joints and cracks. 

Surface Dynamics, 800-584-5553, www.someromatsongroup. 

Booth 1274.

SV1.USA 

SHOW PREVIEW 

Visit us at 

ProMAT Show 

21 - 24 March, 2011 

Booth #3203 

Five models of laser 

guided vehicles 

For high volume consumer goods manufacturers, 

a laser guided vehicle line comes in five 

standard models: counter-balanced narrow, 

counter-balanced wide, single reach, double 

reach and very narrow aisle. These fourthgeneration 

LGVs include AC drives and motors, 

advanced torque control, full Windows-based 

control system, one-piece frame construction, 

standard electrical components, and advanced 

remote support for controls system and components. The 

vehicles interface with block and floor storage, selective rack, 

drive-in rack and gravity flow rack. Elettric 80, 618-433-9290, 

www.elettric80.com. Booth 2031. 

Show pickers tasks, picks with visual WMS 

To streamline putaway, picking and packing, the version 8 of 

the EliteSeries warehouse management system includes a new 

visual logistics paradigm. The new module leverages visual 

communication for system-directed tasks that in a faster format 

that is more understandable by pickers to increase throughput 

and accuracy. The delivers instructions to workers directly on 

their RF gun or handheld computer and visually communicates 

the activities they can execute in an optimum time. Tecsys, 800- 

922-8649, www.tecsys.com. Booth 3872. 

Conveying Loading Palletizing Packaging Sortation/Distribution 

Courier, express and parcels services 

BEUMER sortation and 

distribution technology 

to reach your objectives 

quickly and smoothly. 

Extreme cost-efciency combined with the 

highest sortation capacities for packages and 

parcels of all sizes – these are the demands of 

modern courier, express and parcels services. 

BEUMER sortation and distribution technology 

provides you with a complete high-performance 

system. Individually programmed to meet the 

required conditions, BEUMER sorters win over 

through their creative solutions for the safe, 

fast and gentle handling of packages and 

parcels of any shape or size. You can nd more 

information about the BEUMER company and 

its products on the Internet. 

www.beumer.com 

New products include tugger, heavy-duty 

workstation components, rollers 

Three new product lines include 

the BST automated guided vehicle 

tugger, a 42-mm pipe-and-joint 

system for heavy-duty applications, 

and a roller conveyor system. The 

AGV drives under a stationary cart 

equipped with a BST hitch, extends 

a tow pin to engage the cart and 

moves it to a predetermined location. 

The pipe-and-joint system creates 

heavy-duty structures without 

the need for excessive bracing and 

is ideal for assembly and finishing 

operations where part size and weight require workstations 

with powered height adjustment capabilities, flow racks and 

carts. The Placon roller conveyors deliver stability and smooth 

flow from wide plastic wheels in a variety of sizes to accommodate 

totes with soft bottoms or open cell designs. Creform, 

800-839-8823, www.creform.com. Booth 4814. 

Charger for batteries 

The Legacy Titanium HF industrial battery charger uses 

advanced high frequency, insulated gated bipolar transistor 

charging technology. The charger delivers a high power factor 

and high efficiency to reduce utility demand charges and 

AC consumption. The system constantly diagnoses a battery’s 

condition and adjusts the charge for full, accurate charging. It 

is ideal for tubular, flat plate and flooded lead acid batteries. 

Douglas Battery, 800-211-3684, www.douglasbattery.com. 

Booth 1121.

The Evolution of the Motive Power Charger: LifeSpeed . 

Think of evolution in fast forward. HAWKER’s new LifeSpeed 3000 

charger can charge lift truck batteries to 100% from an 80% DoD 

in just 2 to 3 hours, using a patented algorithm with discharge 

pulses that prevent overheating. 

LifeSpeed : 

• Works with little or no modification to your system 

• Is a fraction of the weight and size of other fast chargers 

• Is fully automatic and adjusts to the battery’s voltage 

• Eliminates the need for truck battery changes so that 

multi-shift operations are able to run on one battery 

• Dramatically reduces space, energy, downtime, and costs 

You also get Battery Boss ® , a compact real-time diagnostic system that 

attaches to the battery and provides detailed performance reports. 

SPEED MEANS MONEY. 

Ask your HAWKER Representative to perform a Harness the Power 

Assessment to see if LifeSpeed is right for your application. 

Visit HAWKER 

at Booth #1827 

at the 2011 

ProMat Show. 

Leading Edge Power Solutions • HAWKER • P.O. Box 808, 9404 Ooltewah Industrial Dr. • Ooltewah, Tennessee 37363 USA 

Ph. (423) 238-5700 • (877) 7HAWKER • Fax (423) 238-6060 • www.hawkerpowersource.com

deniconda ® 

A new generation of spiral conveyors 

deniconda® – an innovative spiral conveyor that 

cleverly compensates for height differences. 

– lightweight, but resilient 

– modular belt with rolling support on the inside 

radius for low power consumption 

– very reliable and low on maintenance 

– modular design 

For more information, just send a mail to 

info@wrh-marketing-americas.com 

Visit us 

Booth 

#3531 

ProM AT 2011 

denipro… 

Unternehmen für fördertechnische Teile und Komponentenbau 

General importer 

WRH Marketing Americas, Inc. 

3150 Brunswick Pike, Suite 220 

Lawrenceville, NJ 08648 

info@wrh-marketing-americas.com 

SHOW PREVIEW 

Single mobile computer 

performs multiple tasks 

Delivering faster real-time data capture 

through its PXA 320 806 MHz processor 

that runs either Windows Mobile 6.5 or 

Windows CE 6.0, the Tecton rugged handheld 

computer performs multiple tasks. 

Multi-range scanning capabilities enable 

bar code reads from 4 inches to 40 feet. 

Features include an easy-grip handle with 

two-finger trigger, molded rubber grip, 

wrist strap, scan vibration signal to verify 

successful scans, and multiple built-in dataentry 

options, including a 3.5-inch touchscreen with stylus, 55 

or 32 key backlit keypads, and voice technology. LXE, 800-664- 

4593, www.lxe.com. Booth 4268. 

ERP suite focused on cost 

reduction, process improvement 

The new release of Epicor 9.05 enterprise resource planning 

suite includes capabilities focused on cost reduction, process 

improvement and customer responsiveness. Available in 50 

countries, the release introduces lean performance metrics, 

enhanced quality assurance, and a focus on both inbound enterprise 

asset management and outbound aftermarket mobile 

service management. Expanded functionality for measuring key 

performance indicators across all operations includes advanced 

financial reporting capabilities, an embedded configurable asset 

management engine, and advanced allocations module. Epicor 

Software, 800-999-6995, www.epicor.com. Booth 3571. 

System helps retailers plan assortments 

based on customer buying habits 

To help retailers predict consumer buying habits, the customerpreference 

planning product monitors purchases and selection 

drivers to help with merchandise and assortment planning. The 

system improves return on investment by matching assortment 

strategy with customer preferences and financial goals with 

tailoring to match local demographics. The system is offered 

as part of the supplier’s planning and forecasting supply chain 

process platform suite, which facilitates interactions among multiple 

software applications. Manhattan Associates, 678-597- 

7274, www.manh.com. Booth 3668. 

Zoned accumulation conveyor 

For handling of medium- to heavyduty 

loads, a zoned accumulation 

conveyor features roll-to-roll chain 

driven live rollers. Zone lengths can be 

configured to coincide with the product 

lengths, with the entire conveyor 

length driven by a single power unit. 

Clutch assemblies are mounted on 

the side frame of the conveyor, with 

the top of each roller as low as 6 inches off the floor, for a low 

profile—ideal for heavy loads and pallet conveying. Rollers are 

offered in diameters of 1.9, 2.5 and 3.5 inches and widths up to 

60 inches, with typical loads weighing up to 6,000 pounds. TKF, 

513-241-5910, www.tkf.com. Booth 2249.

Need a Single Source 

Solutions Provider for 

Your Conveyor Needs? 

Talk to one of 

our Sales Engineers 

and request a frEE quote 

for your next project! 

Many conveyor manufacturers typically only make 

certain types of conveyors. 

At Capitol Conveyors, Inc. we know one size 

doesn’t fit all, that’s why we’re a full service, 

custom manufacturer of many different types 

of conveyors, including specials. 

We also offer complete solutions that include 

systems engineering, equipment, installation 

and commissioning – all with fast, flexible and 

efficient response times. 

• Motorized DriveRoller 

• Lineshaft 

• Belt Conveyors 

• Belt Driven Live Roller 

• Chain Driven Live Roller 

• Gravity 

• Towers 

• In Motion Weighing 

• Automated Print & Apply 

For More Information, Call: 

877-532-9070

SHOW PREVIEW 

Rugged mobile computer 

Offered in handheld and pistol grip versions, 

the Falcon X3 provides real-time 

data capture and communication for 

accurate inventories and enhanced productivity. 

It may be equipped with either 

laser scanner or 2D imager with a read 

feedback function to ensure accuracy. 

The choice is clear. 

InView Transparent, autoclavable polycarbonate for maximum visibility. 

InValuable Lock-in-place design for easy stacking. 

To integrate seamlessly with WMS and 

ERP management systems, the mobile 

computer is packaged with Windows CE 

or Windows Mobile 6.5. For peak communication 

coverage, the device includes 

a Summit Wi-Fi 802.11 a/b/g radio with 

unique diversity antenna. Other features 

include numeric and alphanumeric 

InSight Ultra-Clear Bins 

InReach Molded lip for hooking onto rails or louvered panels. 

InSide Optional clear lids and dividers for added versatility. 

For more information, call 1-800-253-2467 

or visit akro-mils.com/insight now. 

Made in the USA 

keyboards located at the operator’s 

fingertips, a universal numeric phone 

key layout, crisp display and backlit keyboard. 

The computer resists numerous 

drops from 6 feet. Datalogic Mobile, 

800-929-7899, www.mobile.datalogic. 


Double handling capacity 

with spiral conveyor 

To handle double 

the capacity of the 

supplier’s standard 

products, a new 

high-capacity spiral 

conveyor has 

been introduced. 

The conveyors 

ship in one piece 

to reduce time 

and cost of installation. 

Maximum 

load capacity is 75 

pounds per linear foot at speeds up to 

200 feet per minute, meaning the total 

weight capacity in the spiral at any one 

time is 3,600 pounds. For savings in energy, 

as well as controls and system integration, 

only one drive motor is required. 

The spirals can also be configured with a 

high-speed induction conveyor to allow 

loads to enter from several different 

elevations. Ryson International, 757-898- 

1530, www.ryson.com. Booth 1523. 

New swivel technology 

integrated into heavy-duty, 

forged steel casters 

Outperforming 

conventional CNCmachined 

ball raceways, 

kingpinless 

and unit-load bearing 

swivel constructions, 

a new swivel technology 

is offered on the 

supplier’s heavy-duty 

forged steel casters. 

Load capacities 

range from 600 to 

23,000 pounds. The new HPI configuration 

improves the bearing’s element of 

contact to double the number of contact 

points. Equipped with raceways that are 

45% harder than conventional models, 

and a smooth, 16 micro inch finish, the 

casters swivel more easily under heavy 

loads. Hamilton Caster, 800-733-7655, 

www.hamiltoncaster.com. Booth 2662. 


Modular, tear-drop 

connection storage rack 

A universally compatible, tear-drop pallet 

rack system includes four column profiles 

and nine popular beam sizes for maximum 

flexibility in creating and expanding 

pallet rack storage systems. Fully welded 

uprights are roll formed in either four 

or six bend column profiles with 2-inch 

vertical adjustability, and include weld-on 

baseplates, a center reinforcing column 

rib and heavier bracing for strength, 

rigidity and impact resistance. For positive 

beam-to-column engagement, all 

beams feature a patented, rugged automatic 

spring-lock pin mechanism. The 

racks are ideal for selective and high-density 

storage. Ridg-U-Rak, 866-479-7225 

www.ridgurak.com Booth 1241. 

Electric trucks lift 

4,000 pounds 

The E30-40XN series of electric lift trucks 

is available in 3,000 and 4,000 capacities. 

The vehicles include newly designed 

operator compartments, increased 

floor space, auto deceleration system 

to reduce operator fatigue for materials 

handling applications. By utilizing AC 

motors and transistor controller technology 

for the traction and hydraulic 

systems, cost of maintenance is reduced. 

The thermal management system continuously 

monitors the controller and 

motor temperature and, upon identifying 

irregularity, the system protects the component 

by automatically adjusting truck 

performance. Hyster, 800-497-8371, 

www.hyster.com. Booth 1503. 

Patented double 

leg ratchet pallet 

The ProStack double leg ratchet plastic 

pallet features solid construction with 

telescoping double legs to extend its life 

in tough handling situations. The pallet’s 

stringer is oriented 

to prevent 

pallet jack wheels 

from stopping 

on top of it, 

eliminating damage 

when misplaced pallet jacks are overpumped, 

breaking the top deck. Other 

features include a ratchet locking system 

up to four-times stronger than welded 

or snap construction, edge-rackability to 

2,200 pounds, and FM-approved fire retardance. 

For a smooth finish, enhanced stiffness 

and better resistance to impacts, the 

pallets are formed in a gas-assist molding 

process. Polymer Solutions International, 

877-444-7225, www.prostackpallets. 


mmh.com 

Pivoting shelves enhance 

capacity of mobile cart 

The Tip-Up shelf cart includes integrated 

shelves that move and maneuver effortlessly. 

The carts increase storage and 

make part arranging easier. When the 

counterbalanced shelves are lifted, 

pivoting is offset with added weight. 

The shelves automatically lock in place, 

giving the operator full access to the 

entire span without exertion. Shelves are 

loaded from bottom to top, with each 

shelf above tipped up as needed. Topper 

Industrial, 262-886-6931, www.topperindustrial.com. 

Booth 4564. 

Easily replace damaged 

panels on high-speed door 

Featuring 

easily 

replaceable, 

exchangeable 

panels 

made of vinyl, 

mesh, or clear 

PVC, G-2 

high-speed 

roll-up doors can be repaired or modified 

to accommodate seasonal changes 

without down time or destruction to the 

door. Rated for wind loads of 45 miles 

per hour (10 x 12-foot unit), the doors 

automatically reset after impact or blow 

out. Fiberglass extrusions slide securely 

in custom extruded aluminum side 

beams for manual and motorized operations 

including chain hoist, or 12-, 28- or 

36-inches per second. Goff’s Enterprises, 

800-234-0337, www.goffscurtainwalls. 


Dynamic sensor controls 

warehouse lighting 

Unlike conventional 

sensors that 

switch rack and 

warehouse lighting 

fixtures on and off, 

the InteLite dynamic 

sensor provides 

a safe transient 

mode that reduces 

typical aisle or storage 

area lighting 

expenses by 90%. 

Intelligent controls 

activate lighting based on two types of 

motion: transient, which illuminates aisle 

zones with safe, low-level lighting for 

personnel passing through, and task, 

with individual fixtures illuminated at a 

maximum level when sustained activity is 

detected. Orion Energy Systems, 800- 

660-9340, www.oesx.com. Booth 1916. 

Innovative 

Automated 

Solutions 


1-(877)-MECALUX

Automated 

Vertical 

Storage Systems 

It All Adds Up 

To VALUE 

Small parts are expensive. Traditional 

shelving eats up valuable ß oor space 

and exposes parts. WhatÕs more, parts 

can be tough to Þ nd and reach; keeping 

accurate inventories a challenge. 

The Lauyans Small Parts Storage 

System (SPSS) is a USA manufactured 

solution offering high density storage 

utilizing vertical space for greater 

footprint capacity, worker safety, 

security, labor savings and the most 

competitive pricing available. 

Before you decide to buy any 

Automated Storage System, go online 

and check out our pricing. 

www.SPSSonline.com 

It All Adds Up To VALUE 

Lauyans & Company, Inc. 

1-866-LAUYANS (528-9267) 

USA Manufactured 

SHOW PREVIEW 

Compact scissor lift has 

2,000-pound capacity 

The DXL series 

compact scissor 

lifts feature a 

smaller footprint 

than standard 

lifts while 

offering 2,000 

pounds of lifting 

capacity. The 

lifts are ideal 

for work positioning, 

assembly, repair and inspection 

applications in factories, warehouses and 

repair shops. A double scissor mechanism 

allows for a low, 6-inch collapsed height 

while providing a 42-inch raised height. 

To operate the 1/3 horsepower motor, a 

foot switch is included. The unit comes 

equipped with a standard 18 x 30 inch 

platform. Other platforms, including 

oversized tops, may be specified. Presto 

Lifts, 800-343-9322, www.prestolifts. 


Wood block rental pallets 

hold 2,800 pounds 

Used by manufacturers and retailers 

throughout the U.S., Canada and Mexico, 

a wood block rental pallet measures 48 

x 40 inches. Constructed with 26 boards 

and 138 fasteners per unit, the edgerackable 

pallets hold loads weighing up to 

2,800 pounds. Features include 87% top 

deck coverage, non-slip traction in refrigerated 

areas, and no deflection in overhead 

racks. The pallets are made from No. 

2 grade Douglas fir and Southern yellow 

pine lumber that is sustainably forested. 

To control infestation, mold and moisture 

the pallets are kiln-dried; they are not 

treated with chemicals or hazardous materials. 

PECO Pallet, 877-227-7326, www. 

pecopallet.com. Booth 2270. 

Lift up to 50 tons 

with wire rope hoist 

A line of wire rope hoists comes in 

capacities from 25 to 50 tons. The Yale 

Global Max HC double-girder style hoist 

features an external motor to optimize 

cooling and maximize accessibility. The 

remote mounting of the motor and brake 

prevents heat transfer in either direction 

and allows for easy maintenance. The 

hoist includes a sealed, fully enclosed, 

pressure tested gearbox with all gears 

submerged in oil for protection. To eliminate 

slack rope during operation, a fully 

enclosed free loop guide is incorporated. 

Columbus McKinnon, 800-888-0985, 

www.cmworks.com. Booth 1838. 

Truck series lifts up 

to 19,000 pounds 

Offered with a choice of engines, the 

Veracitor VX truck series features low fuel 

consumption, minimal noise, and reduced 

maintenance and operating costs. Both 

cushion and pneumatic tire classes are 

included. Capable of lifting capacities 

from 3,000 to 19,000 pounds, the trucks 

employ a maintenance-free, built-in 

stability system. The rugged powertrain 

incorporates computer-controlled engine 

and transmission, sturdy clutch packs, 

and strong gears and shafts. All transmissions 

have smooth electronic inching to 

cut maintenance costs by eliminating 

periodic adjustments. Yale Materials 

Handling, 800-233-9253, www.yale. 


Modular vertical lifts debut 

Two new modular vertical 

lifts have debuted. 

The Series D direct 

hydraulic lift for medium 

loads includes limited 

moving parts for easy 

maintenance. It is ideal 

for in-plant mezzanine, 

balcony and self-storage 

applications. It features 

carriage sizes up to 6 x 

6 feet, handles payloads 

up to 3,000 pounds, 

and moves loads up to 

15 feet high at a standard 

speed of 17 feet 

per minute. The Series 

B modular lift moves 

boxes, cartons, barrels, 

loose parts and other portable loads to 

and from mezzanines and basements, or 

between two floors. The lift moves loads 

up to 500 pounds to heights up to 20 feet 

at a speed of 40 feet per minute. Pflow 

Industries, 414-352-9000, www.pflow. 

com. Booth 1216.

Voice software supports 

central application 

management 

Version 4.0 of 

Voxware 3 software 

for voice 

picking has 

been released, 

featuring an 

expansion of its 

voice management 

module. The upgrades enable the 

deployment and management of voice picking 

applications from a central data center 

across multiple warehouses of differing 

sizes and layouts. Other features include 

enhancements to order picking, replenishment, 

and putaway applications. To enhance 

open hardware support, the software also 

includes embedded, enterprise-grade 

AirWatch mobile device management 

technology, allowing for secure monitoring, 

management and support of all mobile 

devices in a fleet. Voxware, 609-514-4100, 

www.voxware.com. Booth 3672. 

Automate dimensioning, 

weighing for shipping 

To eliminate freight-carrier chargebacks, 

the CubiScan 150 automates the 

dimensioning and weighing of parcels 

in manifesting/shipping applications. 

It is user-installable, user-serviceable, 

and portable for relocation throughout 

a warehouse. The device is certified to 

a variety of legal-for-trade standards. It 

works in conjunction with the supplier’s 

Qbit data-interface software, allowing it 

to interact with any WMS. Quantronix, 

800-488-2823, www.cubiscan.com. 

Booth 3912. 

IT’S MORE THAN A 

WORK STATION... 

... IT CAN SAVE UP TO 50% IN FLOOR SPACE. 

Building workstations with the Creform System of pipes and joints 

can significantly reduce the amount of floor space needed. Build 

it for one person, a team of six or sixty, there’s no need to use 

more space than necessary to complete the task. Over 700 

Creform components help you expand within existing floor space. 

CRE-356 4.5x4.625.indd 1 

www.creform.com • 800-839-8823 

❑✔ 

Better 

❑✔ 

Safer 

❑✔ 

More Productive 

TALK TO YOUR 

CREFORM 

SALES ENGINEER 

ABOUT 42MM PIPE, 

DOUBLE YOUR 

LOAD W/O DOUBLING 

YOUR COSTS. 

See us at ProMat booth 4814 

1/10/11 12:09 PM 

Decentralized control for 

materials handling 

Movifit intelligent decentralized control 

combines with drive application and communication 

technologies for automotive, 

food and beverage, logistics and other 

materials handling applications. Offered 

in standard IP65 and hygienic washdown 

IP69K-rated construction, the system is 

flexible and scalable in a range of environments. 

Preconfigured control routines 

for horizontal and vertical conveyor applications 

provide ready-to-use functions 

that simplify programming and start-up. 

SEW-Eurodrive, 864-661-1120, www. 

seweurodrive.com. Booth 1555. 

GORBEL, INC. 

585.924.6262 

info@gorbel.com 

WITH GORBEL WORK STATION 

CRANES, YOU CAN HAVE IT ALL. 

• Easy installation 

• Modular design 

• Superior load positioning 

• 5-year warranties 

800.821.0086 • www.gorbel.com 


A warehouse control 

system and new 

technology are the 

heroes at Simon & 

Schuster’s New Jersey 

distribution center. 

By Bob Trebilcock, 

Executive Editor 


modern system report 

Simon & Schuster: 

A twice-told tale 

Every distribution center has 

a story to tell, especially one 

that’s gone through a significant 

system upgrade. Some 

have happy endings, some are thrillers, 

and some are mysteries (What 

were they thinking?). 

The story of Simon & Schuster’s 

600,000-square-foot book distribution 

center in Riverside, N.J., is a little 

like a historical novel, one that unfolds 

carefully over time with a number of 

chapters through the years. Today, the 

facility ships more than 135 million 

units a year, relying on a mix of materials 

handling equipment and technologies 

that have been optimized around 

flexibility and efficiency. That wasn’t 

always the case, but it won’t ruin the 

story if we jump ahead to the end first. 

Most recently, Simon & Schuster 

implemented a new warehouse control 

system (WCS; AL Systems, 

www.alsystems.com) to synchronize 

manual processes, like full pallet and 

pick-to-pallet picking operations, with 

a voice-driven piece picking operation 

that also uses conveyor and a sliding 

shoe sortation system. The WCS also 

updates the warehouse management 

system (WMS) in real time, ensuring 

that all of the components of an order 

arrive at the dock at the right time 

to get best-selling titles to retail and 

wholesale booksellers. 

GraphicCaption Feature 

The improvements also allowed 

Simon & Schuster to consolidate 

order fulfillment operations that 

had been spread across 1.2 million 

square feet in two facilities into the 

one 600,000-square-foot space in 

“We’re shipping 50 

million more books 

and audio CDs than we 

did last year from this 

one facility with fewer 

people than we had in 

the two facilities.” 

—Dave Schaeffer, vice 

president of distribution 

and fulfillment 

Riverside. “We’re shipping 50 million 

more books and audio CDs than 

we did last year from this one facility 

with fewer people than we had in the 

two facilities,” says Dave Schaeffer, 

vice president of distribution and ful- 

PHOTOGRAPHY BY JEFF FUSCO 



fillment. “All told, we increased our 

throughput by 50% while adding just 

20% more manhours.” But, that’s only 

part of the story. 

Setting the stage for improvements 

Simon & Schuster, the publishing division 

of CBS Corp. and one of the best 

known names in consumer publishing, 

was founded in 1924 by Richard 

L. Simon and M. Lincoln Schuster. 

The publisher releases books under 

the Simon & Schuster name as well 

as through such well-known imprints 

as Pocket Books, Scribner, Free Press, 

Atria, Touchstone, Gallery Books, 

Howard Books, Threshold Editions, 

Atheneum Books for Young Readers, 

Little Simon and Simon Spotlight, and 

audio under the Simon & Schuster 

Audio banner. Publishing nearly 2,000 

titles a year that are distributed in more 

than 100 countries, the list of authors 

includes Stephen King, Jodi Picoult, 

Glenn Beck, Vince Flynn, David 

McCullough, Mary Higgins Clark and 

Bob Woodward. Simon & Schuster also 

provides distribution services to independent 

publishers. 

Today, about 70% of Simon & 

Schuster’s annual volume is shipped 

from Riverside; the rest is shipped 

directly to accounts from the printer. The 

facility supports several channels including 

large retail customers like Borders 

and Barnes & Noble; online retailers like 

Amazon.com; wholesale distributors; 

independent bookstores; price clubs 

and mass merchants; as well as a limited 

direct-to-consumer business. 

That wasn’t always the case. The 

Riverside facility was originally built 

in the 1950s by Macmillan Publishing 

Co., which had a significant textbook 

and reference business. When Simon 

& Schuster purchased Macmillan 

in 1995, it already had its own 

Narrow aisle racking and lift trucks 

make the most of Simon & Schuster’s 

storage space. 

600,000-square-foot distribution center 

in Bristol, Pa. 

For years, says Schaeffer, the publisher 

operated both facilities. That’s 

because the two facilities had distinct 

layouts to support unique businesses. 

Simon & Schuster’s facility in Bristol 

was built for the consumer market: 

The facility carried large volumes of 

a relatively smaller list of titles with a 

short life span—the latest bestsellers 

were shipped to Bristol from the printer 

and then quickly turned around to fill 

demand at stores. 

The Riverside facility in its original 

configuration was just the opposite: It 

carried small volumes of a large number 

of SKUs that might remain in reserve 

storage for years. That’s because library 

reference books might have a shelf life 

of many years. “When I started working 

there, we had one title that we had 

only shipped twice in two years,” says 

Schaeffer. 

Originally, Simon & Schuster 

wanted to combine the two facilities 

into Riverside, which had a total of 

48,000 pallet positions. The problem: 

The facilities used different pallet sizes, 

which meant the inventory in Bristol 

wouldn’t fit in the racks in Riverside. 

“We were constantly chasing our tail 

capacity-wise because our volumes 

continued to grow and the Riverside 

facility wasn’t as space efficient as it 

needed to be,” says Schaeffer. 

Starting in 2000, however, Simon 

& Schuster began to write a new distribution 

chapter through a step-bystep 

series of improvements. Each 

incremental improvement brought new 

capabilities and capacities to Riverside 

and laid the foundation for a new order 

fulfillment strategy and consolidation 

of the two facilities. 

44 M o n t h 2 0 0 5 / Modern Materials Handling mmh.com


Cartons are delivered by conveyor 

to and from the order fulfillment and 

mezzanine areas in the facility. 

Writing a new chapter 

The first of those steps involved gaining 

capacity. In 2000, the traditional pallet 

racks in Riverside were converted to a 

very narrow aisle (VNA) storage system 

and VNA lift trucks were added 

to the fleet. That change increased the 

case storage capacity of the building by 

about 45%, says Schaeffer. 

The next year, Schaeffer outsourced 

returns processing to a third-party logistics 

provider, freeing up another 25,000 

square feet in Riverside. In all, those 

two projects freed up about 50% of the 

storage space. 

Those space-saving initiatives were 

followed by three more fundamental 

improvements. In 2004, Simon & 

Schuster consolidated operations from 

a Canadian warehouse into the New 

Jersey facility, increasing volume by 

10%. To accommodate that volume 

plus internal growth, two more shifts 

were added. 

Once the third shift was in place, 

Simon & Schuster took on a series of 

technology and equipment upgrades in 

the 50-year-old facility. 

• In 2005, a homegrown, legacy 

WMS was replaced with a Tier 1 WMS 

package. 

• In 2007, the existing conveyor 

and shipping sorter were upgraded 

to include a high-speed, sliding shoe 

sorter. The combination doubled the 

carton processing speed from less than 

60 cartons per minute to 120 cartons 

per minute. 

• That same year, the staging and 

shipping area was reconfigured and 

upgraded with the addition of four 

stretchwrappers. The palletizing area 

was tripled in size from having room 

to build 120 pallets to having room to 

build 384 pallets. And, additional space 

was created to stage about 1,000 pallets 

for outbound delivery. “We only have 

11 dock doors, so we need to be able to 

stage pallets, especially on peak days,” 

Schaeffer says. 

Designing for flexibility 

Despite those changes, the facility was 

still constrained for space. For instance, 

there might be 25 trailers in the yard 

that still had to be unloaded. “Although 

we have 48,000 pallet locations, at any 

given time, we might have just 100 

positions open,” says Schaeffer. “Since 

we release between 50 and 100 new 

titles a week, if we don’t ship today, we 

can’t receive tomorrow.” 

In addition, the volume of business 

going through the facility is variable. 

“Since we don’t own our own stores, we 

have to respond to customer demand and 

that changes according to how the titles 

are selling in the market,” says Schaeffer. 

“Our inbound order volume can vary by a 

magnitude of five times from a low business 

day to a peak business day.” 

Being able to respond to sudden shifts 

in volume led to more changes with a 

goal of creating a system that is accurate, 

efficient and flexible, especially around 

piece picking. 

Beginning in 2008, Simon & 

Schuster re-engineered the split case 

picking area, replacing a traditional 

serpentine system, where an associate 

picked from pallet flow rack and 

worked his way through the pick zones, 

to a centralized split case picking area 

directed by voice and serviced by an 

automatic case erector and a conveyor 

and sliding shoe sorter similar to the 

shipping sorter. 

To gain capacity, a mezzanine was 

added. That addition created room to 

consolidate the titles still shipped from 

Bristol. Finally, the project included a 

new warehouse control system. That 

measure provided more accountability 

and traceability as cartons traveled 

through the warehouse. “With the new 

system, we can record more information 

for quality control,” says Schaeffer. “In 

the old system, if an order was rejected, 

we had to check it against a lot of paperwork. 

In this system, we scan the ISBN 

number to check the order, which allows 

us to automate the QC processes.” 

Bringing it all together 

Once all of the improvements were 

in place, Simon & Schuster was able 

to devise a new distribution strategy. 

mmh.com Modern Materials Handling / M o n t h 2 0 0 5 45


Simon & Schuster relies on extendable conveyors to receive 

floor-loaded trailers. 

With order fulfillment processes consolidated 

in Riverside, the Bristol facility 

now serves two functions. For one, 

it provides reserve and over-flow storage 

for Riverside. If the inventory for 

a title falls below a 90-day supply in 

Riverside, pallets of inventory can be 

shipped from Bristol to replenish that 

title. In addition, the Bristol facility 

ships seasonal items, such as calendars. 

The Riverside facility is now more in 

tune with an industry that is undergoing 

significant changes as e-books become 

an ever-larger percentage of the business. 

As such, Schaffer sees only modest 

growth in sales volume, but tremendous 

growth in the number of units and 

titles being sold. Attracting additional 

independent publishers as distribution 

clients is an ongoing strategic objective. 

Going forward, Simon & Schuster is 

shipping a smaller number of units per 

title, but more titles than in the past. 

While full pallet and pick-to-pallet 

carton picking operations are still 

directed by RF and bar code scanning, 

the combination of a new WCS, the 

automatic carton erector, conveyor and 

sortation equipment and voice recognition 

technology has driven a new level 

of productivity and accountability in 

the piece picking area. 

“Prior to putting in the carton erector, 

we made all the cartons by hand in 

the pick zones,” says Schaeffer. “Now, 

the WCS directs the movement of the 

cartons from one zone to another.” The 

system can also balance the work load 

by moving the cartons from a zone that 

is taxed to a zone with available capacity. 

“If the next zone is busy, the WCS 

will divert a carton to a zone that is idle 

to optimize the flow through the facility,” 

Schaeffer says. “In the past, we 

were only as fast as the slowest line.” 

As a result, where it once took up to 

7 hours to move a carton through the 

line on a busy day, a carton can now be 

completely picked in 2.5 hours, even 

during a busy period. 

While the old paper picking 

method was accurate, voicedirected 

picking has brought 

improvements in productivity 

and accountability. The 

system, for instance, ties an 

associate to a pick. If there’s a 

problem with an order, “we can 

identify who handled the order 

and find out what happened,” 

says Schaeffer. 

Simon & Schuster has also 

As part of the latest 

improvements, voice 

recognition and a 

sophisticated warehouse 

control system were added 

to improve picking processes. 

implemented an employee incentive 

program that rewards employees for 

exceeding a certain number of picks per 

hour along with a standard for accuracy. 

The most important key to success 

is that everyone working in the facility, 

from the supervisors to human 

resources personnel and company executives, 

learned how to do voice picking. 

“Everyone has become an advocate for 

voice from the top levels of our organization 

on down,” says Schaeffer. 

In addition to throughput and productivity 

improvements, consolidating 

operations at Riverside has saved 

freight, since two orders going to the 

same store may have been shipped 

from two different facilities in the past, 

and improved the customer experience. 

“We constantly got complaints from 

customers because they received their 

order in two different cartons on two 

different days,” says Schaeffer. “Now, 

their order is delivered complete.” 

Despite those improvements, the 

final chapter to the distribution story 

in Riverside has yet to be written. “Our 

next step will be to implement a labor 

management system across the warehouse,” 

says Schaeffer. “With engineered 

labor standards, we believe we 

can achieve greater productivity and 

greater pick rates.” M 



The book on distribution 

The improvements allowed Simon & Schuster 

to synchronize manual processes 

In Simon & Schuster’s new materials 

handling system, a warehouse control 

and warehouse management system 

(WMS) work together with bar code 

scanning and voice recognition technologies 

to manage inventory and orders. 

Receiving: Simon & Schuster gets 

close to 100% advance shipment notifications 

(ASNs) from its printers. Inbound 

freight is scheduled by appointment and 

prioritized by criteria such as how well an 

item is selling. A shipment of a best-selling 

title, for instance, may be given priority 

over a replenishment title. About 80% 

of the inventory received (1) in Riverside 

arrives in full pallet quantities, although 

the facility receives some returns and 

some print-on-demand titles on pallets 

with mixed SKUs. Pallets are unloaded 

by lift truck. New titles that have never 

been stocked before are weighed and 

measured by the cubing and dimensioning 

system to create a profile for storage 

in the WMS. Otherwise, a bar code 

label accompanying a pallet is scanned to 

determine a location on the dock where 

the pallet will be staged (2) for putaway. 

Putaway: Once product is staged 

on the dock, it’s putaway into storage 

within 24 hours. Pallets are picked 

up in the staging area by the swing 

reach trucks that operate in the very 

narrow aisle storage areas (3) and 

are then directed by the WMS to 

a putaway location. The operator 

scans a check digit to confirm 

the putaway location and 

the pallet is now available in 

the system. In the current 

configuration, full cases are 

picked from lower levels in 

the storage area while the 

upper levels are used for 

reserve storage. 

Replenishment: 

Pick waves are run daily 

in the WMS system, 

which also generates 

6 

replenishment orders throughout the 

warehouse based on the stock needs in 

split case (4) and full case picking (5) 

areas. To replenish the split case picking 

modules, for instance, the WMS directs 

an associate to pick the required cartons 

as if they were any other pick. The cartons 

are labeled and inducted onto the 

conveyor system (6) that delivers them 

to the back side of the pick module for 

replenishment. 

Picking: When it comes to picking, 

an order may be filled with a full pallet 

pick (3), split case picks (4), full case 

picks (5), or a combination of the three. 

When the WMS creates an order, it 

will generate tasks in three hierarchies. 

For instance, if a customer asks for 

1,057 books, and there are 1,000 books 

on a pallet and 10 books to a carton, the 

Special 

picking 

9 

4 

Mezzanine: 

Split case 

picking 

4 

7 

Shipping 

10 

Sorter 

Sorter 

12 

11 

Pallet build area 

6 Conveyor 

system 

8 Staging for 

shipping 

6 

5 

Full case 

picking 

6 

3 

Reserve 

storage 

Simon & Schuster 

Riverside, N.J. 

Size: 600,000 square feet 

Products: Books, audio CDs 

Throughput: 11,500,000 units per month 

Stock keeping units (SKUs): 25,000 

Shifts: 3 shifts/5 days per week 

Employees: 225 in operations 

system will generate an order for one 

pallet, five cartons and seven individual 

picks. The system then synchronizes 

the picks so that all of the components 

of that order arrive at the shipping dock 

(7) at close to the same time by supplying 

the warehouse control system 

(WCS) with the carton records for that 

order. The WCS tracks the cartons and 

updates the WMS on the status of the 

order on a real-time basis. 

Pallet picking: This is the most 

straight forward pick. The WMS directs 

an operator to a pick location (3). Once 

the operator confirms the pick by scanning 

a bar code, he is directed to a staging 

3 

Reserve 

storage 

2 Staging for 

receiving 

1 

Receiving 

3 

Reserve 

storage 



System suppliers 

Warehouse control system and voice recognition 

system: AL Systems, www.alsystems.com 

Voice recognition engine: Voxware, www.voxware.com 

Voice recognition devices: LXE, www.lxe.com 

Warehouse management system: Manhattan 

Associates, www.manh.com 

Conveyor system and sorter: Hytrol, www.hytrol.com 

Pushback, carton flow, pallet flow, drive-in and bin 

rack systems: Frazier Industrial, www.frazier.com 

Narrow aisle (VNA) lift trucks: Landoll (Drexel), www. 

landoll.com/mhp/drexel/SL-50/ 

Pallet handling lift trucks: Hyster, www.hyster.com 

Mobile and fixed bar code scanning devices: Psion, 

www.psion.com 

Printers: Zebra Technologies, www.zebra.com 

Weighing and dimensioning: Quantronix, www. 

cubiscan.com 

location (8) on the dock. 

Carton picking: The 

Riverside facility stocks some 

titles that are perennial bestsellers. 

These are stocked in a 

special storage area (9) so they 

can be picked directly to the 

conveyor (6). For the remaining 

titles, picking instructions 

are delivered by the WMS to 

the operator on an RF terminal. 

Cartons are picked to a 

pallet (5), and an operator may 

be picking multiple orders for 

multiple customers. Once the 

pallet is full, the operator drops 

it off at a conveyor induction 

area, where the cartons are 

loaded onto the conveyor (6). They are 

conveyed to a quality control area, where 

the cartons are weighed and compared to 

a calculated expected weight. Following a 

bar code scan, each carton is sorted (10) 

to a pallet building area (11) near the 

dock. Once the pallet is built, it’s stretchwrapped 

and staged (8) on the dock. 

Split carton picking: To initiate 

picking in the split carton area (4), cartons 

are automatically erected and labeled 

with two bar codes that can be scanned 

on two sides. The empty carton is then 

sorted by the WCS to the right zone to 

initiate picking. Picking is directed by 

the voice system. Once all of the items 

in the first zone have been picked, the 

WCS sends the carton by conveyor (6) 

to other zones until all the items for that 

carton have been picked. If the pick 

can’t be completed, the carton will circulate 

until a title has been replenished 

or it goes to a quality control area for 

completion. Once all the items for that 

carton have been successfully picked, 

it’s conveyed to the weighing and cubing 

station. A sorter (12) in between the 

picking areas and the shipping dock (8) 

diverts the last carton of every order to 

a station where the shipping papers are 

added. The carton is then conveyed to 

the pallet build area (11). There the pallet 

is built, stretch-wrapped and married 

to other components of the order on the 

dock (8). 

Shipping: Once all of the components 

of an order have been assembled 

on the dock, they are loaded onto a 

truck for shipping (7). M 


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MODERN special report 

Productivity Achievement 

AWARDS 

Modern’s annual Productivity Achievement 

Awards honor companies that have made outstanding 

strides in improving operations through 

materials handling and related information systems. 

Modern’s editorial advisory board chose 

this year’s winners from a dozen candidates. 

Companies were judged for their ability 

to deliver top-level customer service, respond 

rapidly to changing conditions, deliver orders 

that meet customer requirements, and improve 

operations. In addition, the innovation award 

celebrates a facility that employed a solution 

that defies convention. 

Warehousing/Distribution 

Office Depot 

page 50 

Manufacturing 

Rubbermaid Commercial Products 

page 52 

Innovation 

Cleveland Clinic 

page 54 

2011 WINNERS 



Warehousing/Distribution 

Winner 

Office Depot: 

Flexible 

automation 

Office supply retailer consolidates four locations 

into one new demand-driven distribution center 

that’s powered by mobile robotics. 

When Office Depot executives decided to consolidate 

three distribution centers and a crossdock 

facility into one new state-of-the-art DC in 

Newville, Pa., the office supplies retailer looked for an automated 

materials handling solution that was efficient, flexible 

and able to deliver a competitive edge in the marketplace. 

They found that edge in a goods-to-person picking solution 

featuring two different mobile robots (Kiva Systems, 

www.kivasystems.com). One robot handles cases while a 

larger robot moves pallet loads in the facility that went live 

last year. 

Office Depot believes the time has come for robotics in 

the DC, and it is taking the robotic system deep into its 

operations. Juan Guerrero, senior vice president of supply 

chain, explains, “Along with each picking, we are also doing 

case picking and full pallet movements with the robots.” 

What’s more, Office Depot is using the robotic system 

to manage order fulfillment across all of its sales channels, 

including store replenishment and bulk deliveries 

Read the complete article at: 

www.mmh.com/article/flexible_automation 

to business customers. In all, 100,000 square feet of the 

600,000-square-foot building are devoted to the system 

including the picking stations, which feature 300 robots 

and enough portable shelving space to manage three days 

of inventory. To minimize lift truck travel time, the mobile 

robotic system is augmented by a takeaway conveyor system 

and sliding shoe sorter. The robots have reduced the 

average travel by an associate from 7 miles per shift to less 

than half a mile; meanwhile the order cycle time has been 

reduced from 2 hours to 20 minutes. 

“We believe that the future belongs to the brave,” says 

Brent Beabout, vice president of global network strategy 

and transportation. “We are in a commodity business and 

the supply chain is a differentiator. We plan to be on the 

front end of that.” 

Starting from scratch 

Office Depot is a leading supplier of office products and services, 

with more than $12 billion in revenue and 1,500 retail 

locations in 52 countries. The Newville DC was a result of 

a growth strategy that has been driven by acquisitions that 

brought new retail locations under the Office Depot umbrella 

and added warehouses and distribution centers. A few years 

ago, Office Depot had 33 buildings in its network, which 



Photography by Alan Wycheck 

came in two styles: crossdocking centers 

to replenish retail locations and DCs to 

service business customers and direct-toconsumer 

Internet and catalog orders. 

Using the recession to review its 

network and optimize its systems, the 

company has reduced that number to 

17, with a goal of reducing it to 12. To 

reach that number, Office Depot has 

closed and consolidated some facilities 

and upgraded the capabilities in 

remaining facilities. Newville, which 

serves 107 stores in the Northeast, 

was different. In that region, where the 

retailer operated four facilities with a 

total of 829,408 square feet, there was 

a unique opportunity to reduce the 

overall footprint of operations by building 

a new facility. 

Guerrero and Beabout wanted a system 

that could integrate with its homegrown 

warehouse management system 

to handle every line of business and 

sales channel where it operates. And, 

they wanted the flexibility to scale during 

seasonal periods or as the overall 

business managed by the system grows. 

Finally, and most importantly, the 

system had to have the capabilities to 

manage Office Depot’s transition to a 

true, demand-driven distribution network. 

In the new pull model, every 

store will get a just-in-time delivery 

nearly every day of the week. 

After looking at traditional pick and 

pack solutions, Guerrero and Beabout 

chose mobile robotics. The system uses 

a small robot to move mobile storage 

devices to and from associates at workstations, 

and a larger vehicle designed 

to handle full pallets. Once picks have 

been completed, the robots deliver 

the units to a conveyor induction station, 

where the shipping containers are 

placed on a conveyor and sliding shoe 

sortation system and are sorted to a shipping 

lane. 

Several factors led to this choice: 

Goods-to-person: The robots bring 

product to the associate’s workstation, 

saving steps. In addition to productivity 

improvements, the system was very accurate, 

which would reduce picking errors. 

Dynamic slotting: The robotic system 

monitors the movement of SKUs 

and slots the fastest moving items closest 

to the workstations. That leads to 

better use of the robots and minimizes 

the size of the fleet required. 

Proven and reliable: Performance, 

recovery times from failure and risk 

management were robust enough for 

the Office Depot operation. 

Flexible and scalable: What 

tipped the scales was productivity, the 

ability to co-mingle and pool inventory, 

flexibility to handle pieces, cartons and 

pallets, and the ease of adding to the 

Bob Zelis, senior director (left) 

and Brent Beabout, vice president 

of global network strategy and 

transportation 

system in the future. 

While mobile robotics is providing 

answers in Newville, that doesn’t mean 

Office Depot will adopt the technology 

everywhere. Beabout says, “We will 

assess each facility individually going 

forward. However, this was the right fit 

for this facility and our overall supply 

chain objectives.” 


Mobile robotic picking solution: 

Kiva Systems, 781-221-4640, 

www.kivasystems.com 

Conveyor, dock conveyor and sliding 

shoe sorter: Dematic, 877-725-7500, 

www.dematic.com 

Rack: UNARCO Material Handling, 

800-862-7261, www.unarcorack.com 

Lift trucks: Crown, 419-629-2311, 

www.crown.com 

Bar code scanning: Motorola, 

800-722-6234, www.motorola.com 

Print and apply: Pyramid Controls, 

513-679-7400, www.pyramidcontrols.com 

System design and integration: Office 

Depot, including a proprietary warehouse 

management system 



Manufacturing 

Winner 

Rubbermaid: 

Manufacturer retrofits 

warehouse with AS/RS 

By updating an aging manual storage system with 

automated cranes, Rubbermaid Commercial Products 

reduced costs and improved safety. 

Reduce, reuse and recycle. Those are the three R’s 

of the sustainability movement. Going green may 

not have been one of the reasons Rubbermaid 

Commercial Products chose to retrofit a manually operated, 

high-bay warehouse with automated storage and 

retrieval cranes (Dematic, formerly HK Systems, www. 

dematic.com) at its 750,000-square-foot manufacturing 

plant and DC in Winchester, Va., but the three R’s are certainly 

in play. 

The company was able to reuse and recycle the existing 

rack infrastructure in a 20-year-old, high-density storage 

area containing 56,500 pallet positions in 200,000 square 

feet. Meanwhile, by replacing 10 aging manually driven 

stacker cranes with 28 automated cranes, Rubbermaid 

reduced the labor, created a safer work environment, and 

provided room for future growth. 

Launched in November 2008, the project unfolded in 

four steps over 11 months 

• choosing a solution and vendor, 

• designing the system and processes, 

• preparing for installation, and 

• finalizing installation. 


www.mmh.com/article/rubbermaid_products 

It was a textbook example of solid design and project 

management coming together to deliver productivity gains 

with materials handling automation. 

Time for renewal 

Winchester, Va., is the headquarters for Rubbermaid 

Commercial Products, a division of Newell Rubbermaid 

that manufactures a diverse line of products for business 

customers including waste management, facilities maintenance 

and materials handling products. The Winchester 

facility employs 800 associates, stocks about 7,000 SKUs 

and ships nearly 1,800 pallets a day in a 24/7 operation. 

Two years ago, the division purchased Technical 

Concepts, a company that distributes complementary products. 

This had an impact on the shipment profiles. “In the 

past, we primarily shipped large units such as trash cans that 

might have been stacked 20 to a pallet,” says John Elliott, 

senior distribution engineer. “Today, we might also ship a pallet 

with 10,000 air fresheners.” 

The 28-aisle, high-bay, high-density storage area was 

installed in 1989. Seventy-feet tall, it featured 10 manually 

operated stacker cranes. Six aisles were dedicated to components, 

materials and work-in-process to support manufacturing 

while the other 22 aisles stored finished goods. 

After 20 years, the system had become expensive to operate 

and maintain. There were also safety concerns, so the time 

was right for a new system. 



The right solution 

In the early stages of the evaluation 

process, Rubbermaid considered 

several proposals to update with 

another manually operated system. 

The proposal to automate with 28 

aisle-dedicated cranes came later, 

after the team thought they were 

moving forward with a smaller-scale 

automated solution. Two things 

changed. 

First was the introduction of 

a rotating fork materials handling 

device that can operate in a very 

narrow aisle and be retrofitted to 

a building with standard post-andbeam 

rack. The crane extracts a 

pallet from a storage location then 

rotates 90 degrees so the profile of 

the load is no wider than the overall 

profile of the storage and retrieval 

crane. The crane rotates 90 degrees 

again to put a pallet away in a storage 

location. 

Second was that vendors were 

sharpening their pencils as they put 

their quotes together. On paper, the 

combination of automation, improved 

productivity and labor savings made 

the most sense. 

Scoping the project 

Between November 2008 and April 

2009, Rubbermaid assembled a 

project team that included operations, 

maintenance and IT, and representatives 

from relevant vendors. 

IT representatives planned how 

different systems would communicate 

with each other and hand-off 

instructions. The team also decided 

to let its WMS continue determine 

putaway and retrieval locations and 

made necessary modifications and 

changes to the network, programmable 

logic controls and Ethernet. 

The next phase was to map all 

the process steps for the machines 

and cover every eventuality because 

without an operator, decisions and 

adjustments would now have to 

be controlled by automation. That 

required building logic for different 

sized products and different sized 

rack locations, new controls for the 

conveyor system, and a validation 

process to prevent the wrong pallets 

from being inducted into the system. 

A new system created an opportunity 

to optimize the flow of 

materials, especially hot orders. In 

the past, if a hot order came into 

the system, a crane operator could 

retrieve a pallet and drop it off at 

an outbound station for pick up. 

Now, the system can change the 

priority of the picks. If there are 

already pallets staged on the outbound 

conveyor, the system will 

bump up the priority of the pallets 

in the way so the crane can deposit 

the hot item for pickup. 

Laying the foundation 

By February 2009, the cranes were 

in production. Rubbermaid began 

installing wiring and data drops for 

the controls and machines and welding 

together the floor rails. The rails 

were put to the side of the aisles so 

the old cranes could continue to 

operate since Rubbermaid expected 

to install the system piecemeal. 

In April, the team visited the 

crane manufacturing plant to view 

a system test that successfully 

handled a load that matched 

Rubbermaid’s biggest load. 

Implementing the system 

In May, the first aisle was 

shut down to install the first 

crane. It took three weeks, and 

required only minor modifications 

and changes to the logic in 

the WMS to better match the 

physical locations to the product. 

Rubbermaid installed the 

remaining 27 cranes in about 16 

weeks. 

By October 2009, work 

was complete, the system was 

operational and productivity 

was improved. “We now have 

a system with reliable equipment 

that accommodates our 

needs today and will grow with 

us in the future,” says Elliott. 


John Elliott, senior 

distribution engineer 

Systems integration, automated storage 

and retrieval cranes: Dematic, formerly HK 

Systems, www.dematic.com 

Warehouse management system: Manhattan 

Associates, www.manh.com 

Drive in, pallet flow and case flow rack: 

Mecalux, www.interlakemecalux.com 

Lift trucks: The Raymond Corp., 

www.raymondcorp.com 

Bar code scanning: Psion, www.psion.com 

Conveyor and carton sortation: Intelligrated, 

www.intelligrated.com 

Conveyor control system: Pyramid Controls, 

www.pyramidcontrols.com 

Stretch wrapping: Lantech, www.lantech.com 

Extendable conveyors: Stewart Glapat, 

www.adjustoveyor.com 

Tuggers: Motrec, www.motrec.com 

PHOTOGRAPHY BY JEFF Hutchens 



Innovation 

Winner 

Cleveland Clinic: 

A prescription for 

health care reform 

A premier medical center transformed a manual, paper-based 

warehouse into a state-of-the-art facility using automated 

technologies to deliver supplies to 14,000 locations. 

A 

sign outside the new 227,000-square-foot service 

center underneath the Cleveland Clinic’s 

parking garage says it all: Service to our patients 

starts here. 

“That is our motto,” says Jeff Pepperworth, senior director 

of materials management for the clinic, one of the 

nation’s premier medical facilities. “We are picking an average 

of 70,000 units a day and many of those are critical to 

the treatment of a patient.” 

To live up to that motto, the clinic went through a logistics 

version of health care reform: Pepperworth and his team visited 

medical centers in Europe to design a system with capabilities 

similar to a just-in-time manufacturing environment 

and a direct-to-consumer e-fulfillment operation. 

The result is a state-of-the-art distribution and order 

fulfillment center that went live in September 2008. The 

facility manages the delivery of product from five unique 

operating departments—everything from pharmaceuticals 

and surgical kits to meals and linens—to 14,000 employees 

in buildings across the 168-acre campus. 


www.mmh.com/article/cleveland_clinic 

System components include: 

• Eighty RFID-enabled automatic guided vehicles (AGVs) 

that identify and deliver more than 1,100 RFID-enabled 

carts, 

• Light-directed picking from seven horizontal carousels 

with a total of 7,200 storage locations, a vertical carousel 

and carton-flow rack. The facility also has 850 pallet 

storage locations, 

• Conveyor, lift trucks, reach trucks and man-aboard lift 

trucks for materials transportation, 

• Information and automatic identification systems 

including enterprise resource planning (ERP) and warehouse 

management systems (WMS), and bar code and 

RFID technology, and 

• Automatic battery charging to ensure that the AGVs are 

always in service. 

Bringing materials handling up to speed 

Founded in 1921, today the Cleveland Clinic is the largest 

hospital system in Northeast Ohio. Its main campus has 26 

health institutes; 1,300 beds; 3.3 million patient visits; and 

more than 50,000 hospital admissions a year. 

Several years ago, the clinic launched an initiative to add 

1.5 million square feet of clinical space, including new cardiac 

and urology facilities. With the anticipated increase 


Jeff Pepperworth, senior director of 

materials management 

in the volume of patients, the clinic 

needed to upgrade its systems. 

The clinic set several goals: 

• Centralize materials management: 

The new facility would bring together 

materials management for the linen 

department, patient food, waste management, 

pharmaceuticals and surgical 

supplies, general supplies and the 

retail operations under the management 

of one system under one roof – a roof 

located below ground and linked to the 

main hospital by a series of tunnels. 

• Handle vertical and horizontal 

travel: The system had to manage deliveries 

to depots, or central queue areas, 

on the warehouse level (horizontal 

delivery) then track product to the right 

destination (vertical delivery). 

• Respond quickly to demand: The 

clinic wanted to maintain several days of 

inventory for most products, which called 

for accurate inventory management and a 

system to quickly replenish supplies. 

• Scale up or down according to 

patient levels: Initial plans called for 

picking 30,000 items a day. The system 

has been able to flex to meet the patient 

load that has grown as a result of bringing 

new facilities online. 

• Implement with no shutdown: 

Finally, the clinic needed to operate 

24/7 while implementing new systems. 

A new model 

From the start, the team was working 

without a template: Pepperworth and 

his colleagues visited health care facilities 

in Europe and industry warehouses 

in the United States where automated 

materials handling systems were up and 

running. As a result, the clinic selected 

a variety of automated materials handling 

solutions to meet its goals. 

At the heart of the system are 81 

AGVs, each capable of moving up 

to 1,000 pounds. Product ready for 

delivery is stored on carts that are 

automatically picked up by one of the 

vehicles then transported through the 

tunnel system to a depot where carts 

are staged. Clinic delivery personnel 

pick up the carts then deliver them to 

the right destination. 

The AGVs are enabled with an RFID 

reader that scans an RFID tag on the 

bottom of every cart. Through that 

scan, the AGV verifies that it is picking 

up the right cart for delivery; the RFID 

tag allows the system to track the AGVs’ 

location. 

The clinic also installed opportunity 

battery charging stations throughout 

the tunnel system and storage areas. In 

between moves, an AGV will go to the 

nearest station for a battery charge. 

While AGVs are the most visible 

materials handling technology, they 

aren’t the only automation. Horizontal 

carousels are used in the primary 

materials management area to store 

and pick items with a relatively small 

cube. Horizontal carousels in the 

pharmacy area provide space-saving 

storage and added security. A vertical 

carousel stores documentation and 

literature. 

Finally, to ensure accuracy, the system 

captures data throughout the delivery 

process. In addition to an RFID 

scan by the AGV, associates scan a personal 

identification bar code and a bar 

code on the cart when they pick up a 

cart at one of the staging depots. They 

are also required to scan a bar code to 

verify that they are at the right floor 

when they get off the elevator, and to 

capture an electronic signature to confirm 

accurate delivery. 

The system was operational from day 

one. And as the clinic continues its mission 

of delivering quality care, the warehouse 

is supporting that mission. M 


modern productivity solution 

LEAN and grEEN pALLEts 

With a presswood pallet, 

Lincoln Electric is not only 

meeting European export 

requirements and streamlining 

its pallet inventory, it’s reaping 

sustainability benefits. 

By Noël P. Bodenburg, 

Executive Managing Editor 

Lincoln Electric, a Cleveland-based manufacturer 

of arc welding machines and consumables, 

was looking to better meet export shipping requirements 

for its pallets, which were sometimes held 

up for inspection in Europe. 

Lincoln was purchasing construction-grade 

pine and making export pallets in-house. “We were 

shipping nine different products and each had its 

own unique pallet design,” says Tom Soster, manufacturing 

engineering manager for Lincoln Electric. 

In addition to maintaining an inventory of nine different 

sizes that took up valuable space on an apron 

in the dock area, the pallets had to be bark free and 

made from heat-treated lumber to meet European 

regulations for pallets. 

A presswood pallet (Litco International, www. 

litco.com/presswood-pallets.htm) offered a number 

of benefits to Lincoln. The pallets are manufactured 

using an environmentally responsible process 

that molds wood waste and wood byproducts 

under high heat and pressure, the pallets are ISPM 

15 approved wood packaging and are guaranteed to 

be free of bugs, bark and mold. The pallets are also 

available in a half pallet size, measuring 24 inches 

x 40 inches—an ideal size for Lincoln’s welding 

machines. 

“We received some samples of the pallet and by 

February 2009, we had changed over our first product,” 

says Soster. “On our first shipment, we learned 

that presswood pallets are common and welcomed 

in Europe. It was a very easy transition.” 

The pallets also complement Lincoln Electric’s 

initiatives to stay lean and green: Since they are 

nestable and cradle-to-cradle certified, they free up 

valuable dock space previously dedicated to pallet 

storage and can be recycled at the end of their life. 

Since then, Lincoln has changed eight additional 

pallets over to presswood pallets, delivering an estimated 

5% savings on the cost of the pallets. And, 

Lincoln can order the pallets on an as-needed, justin-time 

basis from a local distributor. 

“The ability to order based on what we need 

means we can run a leaner operation,” says Soster. 

“And, since they nest, we can bring 50 pallets at 

a time into the product area instead of 25. That 

means fewer trips to move pallets.” 

As an additional benefit, the presswood pallets 

are recyclable and earned a silver cradle-to-cradle 

certification from MBDC, an organization that 

assesses the sustainability of a product and the 

practices employed in making it. 

“Like most responsible organizations, Lincoln 

Electric is concerned about sustainability,” says 

Soster. “Using a presswood pallet is not only meeting 

our shipping requirements, it’s making us a little 

more green.” M 


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Protective rails installed at the base of 

a rack system can safeguard against 

accidental impact and damage. 

modern Equipment 101: Pallet rack 

A primer for warehouse/DC managers 

Behind the 

backbone 

By Lorie King Rogers, 

Associate Editor 

Pallet rack is 

a fundamental 

component that can 

maximize storage space 

and have a positive impact on 

organization, productivity and 

throughput in your facility. 


If you’ve ever taken a placement 

exam, you might recall those 

analogy questions: “A is to B as 

C is to D”? Here’s one: Pallet 

rack is to a warehouse as a skeleton 

is to a body. Both provide 

structure and support to an overall 

entity. And, if part of either is broken, 

it’s very painful. 

As end users expand their existing facilities 

or build new warehouses, new pallet rack 

is likely to be part of the conversation. What 

are most companies using today? “The shift in 

rapid order fulfillment has impacted the types 

of systems that are in demand,” says Dave 

Olson, national sales and marketing manager 

for Ridg-U-Rak (www.ridgurak.com). “End 

users are still looking for selective rack, but 

there’s been more activity in recent years in 

flow systems and multi-level pick systems for 

rapid fulfillment.” 

There are great reasons to have either traditional 

rack or sophisticated rack for automated 

storage and retrieval systems in your facility. Both 

can have a significant impact on an operation’s 

ability to maximize inventory turns, minimize the 

amount of product on hand and turn it rapidly. 

Efficiency continues to be a driving force in 

the materials handling industry, and the right 

racking solution in a warehouse can represent 

a company’s ability to remain competitive in the 

global marketplace. Proper planning can ensure 

complete and total efficiency in any warehouse,” 

says Linda Demke, CEO of Interlake Mecalux 

(www.interlakemecalux.com). “This permits the 

customer to establish a system that allows them 

to accurately understand all aspects of their 

inventory. Consequently, they are able to make 

quick and smart decisions and ultimately stay 

ahead of the competition.” 

To determine which rack is right for your 

operation, let’s go back to basics. 

Pallet rack systems are a key component of 

any warehouse or distribution center, and one 

of the most important tools in the materials 

Racking systems can be configured as stand-alone storage 

solutions, and they can also be specially designed to work 

with automated storage and retrieval systems. 




Primary pallet rack suppliers 

Most rack suppliers provide all of the basic pallet racking systems: selective; double-deep; drive-in; drive-through; gravity flow 

and push-back rack. Choice of steel and method of construction vary by company. 

Company Web Site Telephone Headquarters 

Steel 

structural 

Rollformed 

Advance Storage advancestorage.com 888-478-7422 Huntington Beach, Calif. x x 

Products 

Boston Rack bostonrack.com 508-230-5755 North Easton, Mass. x x x 

Bulldog Rack Co. bulldograck.com 866-285-5725 Weirton, W. Va. x x x 

basemfg.com 770-207-0002 Monroe, Ga. x x x 

Elite Storage 

Solutions 

Uprights 

Welded 

Engineered engprod.com 864-234-4888 Greenville, S.C. x x x 

Products 

Equipement Boni equipementboni.com 450-653-1299 Quebec, Canada x x x 

Frazier Industrial frazier.com 800-614-4162 Long Valley, N.J. x x 

Hannibal Material hannibalindustries.com 800-967-7009 Los Angeles, Calif. x x x 

Handling 

Interlake Mecalux interlakemecalux.com 877-632-2589 Melrose Park, Ill. x x x x 

Konstant konstant.com 888-566-7826 Oakville, Ontario, Canada x x x x 

LB International loadbank.com 800-458-9010 St. Cloud, Fla. x x x 

Lyon Workspace lyonworkspace.com 800-433-8488 Aurora, Ill. x x x 

Products 

Nedcon USA nedcon.com 513-367-2656 Harrison, Ohio x x 

Pacific Westeel pacificwesteel.com 866-473-3472 Oakville, Ontario, Canada x x x x 

Penco Products pencoproducts.com 800-562-1000 Skippack, Pa. 

Ridg-U-Rak ridgurak.com 866-479-7225 North East, Pa. x x x 

Schaefer Systems ssi-schaefer.us 800-876-6000 Charlotte, N.C. x x x x 

International 

SPG (formerly spgusa.com 800-722-5255 Prospect Heights, Ill. x x 

Jarke) 

SpaceRak spacerak.net 800-336-3926 Wills Marysville, Mich. x x x 

Speedrack Products speedrack.net 800-752-7352 Sparta, Mich. x x x 

Group 

Steel King steelking.com 800-826-0203 Stevens Point, Wisc. x x x 

Twinlode twinlode.com 800-535-6719 South Bend, Ind. x x x 

Unarco Material unarcorack.com 800-862-7261 Springfield, Tenn. x x x 


Wireway Husky wirewayhusky.com 800-438-5629 Denver, N.C. x x 

Bolted 

handling industry. Variations of these 

steel structures keep product organized, 

provide storage, and maximize 

cube space from floor to ceiling. More 

importantly, they are central to getting 

product out the door. “A good rack 

system literally and figuratively supports 

order picking,” says Kevin Curry, 

national account manager for Steel 

King (www.steelking.com). 

Basic pallet rack consists of upright 

steel frames connected by horizontal 

steel beams. Pallets rest on the beams 

between the upright frames. Two 

frames and the corresponding beams 

create a bay. The number of pallet positions 

in a bay depends on the height 

of the frames and the spacing of the 

beams. High-rise storage systems can 

reach 100 feet, but 20 to 25 feet is a 

typical rack height. 

The components of the upright 

frames—the steel posts and cross 

braces—can be bolted or welded together. 

Bolted construction is more prevalent in 

Europe, while welded frames are more 

common in the United States. 

There are also two ways to connect 

beams and frames: The components 

can be bolted to frames or interlock 

using a slotted connection system. 

Rack components can be made of 

structural steel or roll-formed steel, 

with roll-formed being the most common 

in the United States. Structural 

steel typically costs about 5% to 10% 

more than roll-formed. According to 

Olson, raw materials make up a significant 

part of the cost of rack. For that 




This high-density pallet rack storage system uses an 

electric cart to load and unload pallets, saving time and 

minimizing forklift incidents. 

reason, any increase in the price of 

steel will drive a percentage increase in 

the cost of the finished rack. 

Rack systems can generally be divided 

into two broad categories: low-density 

systems that allow easy access to product, 

or high-density systems that make better 

use of space but limit access to stored 

Protect the code, track the load 

Streamlined movement in and around 

pallet racking is crucial to an operation’s 

overall success. “About 80% of 

all industrial storage is on pallet rack,” says 

Frank Ceriello, vice president of sales for 

Aigner Index (www.aignerindex.com). “The 

ultimate goal is to know where everything 

is—all of the time.” 

Bar codes provide a wealth of product 

data, but in a harsh warehouse environment, 

the quality of a bar code label can be 

compromised if it isn’t protected properly. 

An unprotected bar code label can be 

damaged by dust, dirt, grease, moisture 

or smudged label ink. Then it might not 

scan or it might scan inaccurately. Either 

scenario can cause serious and expensive 

shipping and inventory problems, not to 

mention the impact it could have on customer 

relations. 

One simple solution for bar code protection 

is clear insertable plastic label holders. 

Available in many styles, these holders 

typically cost less than 5% of the total warehouse 

expenses and can generate returns 

in improved productivity, inventory accuracy, 

knowledge of product location, and 

flexible designation or location changes. 

Once product is located, tracking its 

product. Here’s look at 

what the different systems 

offer. 

LOW-DENSITY 

RACK 

Single-deep rack 

Single-deep rack, or 

selective rack, is the 

most common type 

used in warehouses 

and distribution centers. 

Since loads are 

stored one pallet 

deep, this is the lowest 

density storage 

of any system, but it 

allows unimpeded 

access to every pallet. It can be used 

in a number of aisle configurations and 

can be paired with any type of lift truck. 

Single-deep pallet rack is also the 

least expensive rack option. According 

to “Rules of Thumb,” a pricing guide 

published by TranSystems, standard 

Plastic label holders (top) can 

protect the bar codes on pallet rack. 

Ceiling-mounted sensors (bottom) 

can help locate a forklift and identify 

the cause of rack damage. 

selective pallet rack costs about $50 to 

$75 per pallet position. 

Double-deep rack 

Aptly named, double-deep rack stores 

one pallet load behind another in a 

structure that’s twice as deep as singledeep. 

This design doubles storage, but 

it limits access and flexibility. 

To access the rear pallet load, the 

front pallet position must be empty. 

Double handling is necessary unless pallets 

are stored on a last-in/first-out basis. 

In most cases, two pallets with the same 

product are stored in a slot of a doubledeep 

rack, which limits flexibility and 

requires a deep-reach lift truck to access 

loads in the rear position. 

“Rules of Thumb” lists double-deep 

rack at $65 to $90 per pallet position. 

HIGH-DENSITY RACK 

Drive-in rack 

Drive-in rack can be configured to store 

loads four or more deep, creating very 

movement and operator performance 

can also pay off big. “Complete visibility 

to vehicle movement can bring gains in 

labor productivity, fleet optimization and 

safety,” explains Sarah Brisbin, vice president 

of marketing for Sky-Trax (www. 

sky-trax.com). 

To determine the location of a forklift, 

a sensor mounted on top of the 

vehicle reads the optical position markers 

mounted in the racked area. The 

system can pinpoint the forklift to within 

a square inch the facility. 

Special system reporting packages 

can measure distances traveled and 

time taken to complete a task. Traffic 

reports can identify bottlenecks and 

collisions. With this tracking system, 

users can go back and replay the data 

to see which truck contacted the rack 

and why. It can also determine who 

was driving and what was he carrying. 

Finding the answers to these questions 

quickly could identify the need 

for additional operator safety training, 

uncover a process flaw, or identify a 

damaged rack that requires immediate 

attention to prevent disaster down the 

road. 




dense storage. For example, a drive-in 

system that stores pallets four high and 

five deep can hold 20 pallet loads in 

each bay. 

In a drive-in system, lift trucks drive 

into the front of a storage bay, place a 

load in the designated position then 

back out. The rack is designed without 

traditional beams across the bays 

so lift trucks can maneuver in and out. 

Instead, pallets rest on rails that run 

along the inside of the bay, perpendicular 

to the aisles. 

Pallets are stored on a last-in/firstout 

basis. Each bay is typically dedicated 

to a single product, so drive-in 

rack is best used for storing large quantities 

of the same product. They work 

well where an entire bay of product is 

moved at once, such as in staging product 

for shipping. 

According to “Rules of Thumb,” standard 

drive-in rack costs $80 to $105 per 

pallet position for systems two loads 

deep, $75 to $105 for three loads, and 

$75 to $100 for four or more loads deep. 

Drive-through rack 

Drive-through rack is almost the same 

as drive-in, except that drive-through 

rack allows lift trucks to enter from 

either end. This means an aisle is 

required at both ends of the structure, 

but it increases access to pallet loads 

and can be loaded from one end and 

emptied from the other, enabling firstin/first-out 

product rotation. 

According to “Rules of Thumb,” 

drive-through rack costs $80 to $120 

per pallet position for systems two 

loads deep, $80 to $115 for three loads, 

and $80 to $110 for four of more loads 

deep. 

DYNAMIC STORAGE 

Gravity flow rack 

Gravity flow rack combines a stationary 

rack structure with skate wheel or roller 

conveyor to create a dynamic storage system. 

Pallets are loaded into the back end 

of the rack then travel down the slightly 

inclined lane of conveyor so they can be 

retrieved from the front of the system. 

R-Mark marks the rack 

If good rack goes bad, the results can be 

catastrophic, even deadly. So pallet rack 

suppliers have established strict technical 

guidelines to ensure product integrity 

and overall safety. To be sure the rack 

you’re considering meets these guidelines, 

look for the R-Mark. 

The R-Mark Certification program 

is administered by the Rack 

Manufacturers Institute (RMI, www. 

mhia.org/industrygroups/rmi), an 

industry group within the Material 

Handling Industry of America (MHIA). 

To earn the R-Mark, rack manufacturers 

must submit sets of product data 

which is studied by RMI engineers to 

Flow rack systems provide highdensity 

storage by storing product many 

pallets deep. Because each layer of flow 

rack is typically dedicated to a single 

product, these systems offer less storage 

flexibility than selective rack but 

more than drive-in or drive-through. 

This is a good option for storing dated 

products because it allows easy rotation 

of inventory on a first-in/first-out basis. 

It can be used for picking by the piece, 

carton or pallet. Carton flow rack that 

stores individual cartons are also available 

from many manufacturers. 

Because there is more engineering 

involved in creating flow racks, they 

are more expensive than selective rack. 

According to “Rules of Thumb,” flow 

rack costs $135 to $260 per pallet position 

for systems two loads deep and 

$250 to $400 for three or more loads 

deep. 

Push-back rack 

Push-back rack combines a stationary 

rack structure with nested carts that 

move along inclined rails. The first pallet, 

which is loaded from the front, is 

placed on top of the cart. When the 

second pallet is loaded, it pushes back 

the first pallet, exposing the second 

cart, and so on. 

Usually configured two to five pallets 

deep, these systems offer dense 

storage. Like flow rack, push-back rack 

does not require a lift truck to enter the 

ensure the suppliers’ testing, calculations 

and resulting rack capacities 

meet the most current standards. 

Only after product data is shown 

to meet the guidelines does RMI issue 

the R-Mark seal. Manufacturers are 

then authorized to use the R-Mark 

seal on published capacity charts and 

designs and display it on products 

built according to those designs. 

You can visit the RMI Web site for 

the latest versions of rack standards 

(including MH16.1-2008-Specification 

for Industrial Steel Storage Racks and 

MH26.2-200-Specification for Welded 

Wire Rack Decking). 

racking structure or require an entire 

bay to be dedicated to one product. 

Unlike flow-rack, however, push-back 

rack manages inventory on a last-in/ 

first-out basis and requires less space 

than flow-rack because rear access is 

not necessary. 

According to “Rules of Thumb,” 

push-back rack costs $110 to $140 

per pallet position for a double-deep 

system and becomes more expensive 

as carts are added—$130 to $170 for 

three deep, $155 to $200 for four deep, 

and $175 to $220 per pallet position for 

a system five loads deep. 

Protect your investment 

With so much riding on your rack, it’s 

wise to protect your investment. Rack 

damage is the biggest risk to users, 

so replacing damaged components 

is critical, says Steel King president 

Jay Anderson, who is also the current 

president of the Rack Manufacturers 

Institute (RMI, www.mhia.org/industrygroups/rmi). 

All rack manufacturers 

offer a variety of options and accessories 

that reduce potential damage 

to rack structure, he says, and advises 

making the investment in protection. 

Don’t skimp on protection or prevention. 

“Nothing lasts forever, and wear and 

tear can take its toll,” adds Curry. “Actually 

walk the aisles and inspect your rack frequently. 

This preventive step could save a 

major headache later on.” M 


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modern special report 

Reader survey: 

Conveyors are the most used form of 

automation in today’s plants and distribution 

centers. Modern readers told us how they’re 

putting the technology to work. 

By Bob Trebilcock, Executive Editor 

When it comes to automated materials handling 

equipment, end users are most likely 

to turn to conveyor to speed up the flow of 

product in their plants, warehouses and distribution centers. 

Take crossdocking, for instance. Without conveyor, it’s hard 

to imagine how else to get thousands of cartons from the 

receiving dock to the shipping dock in 10 minutes or less. 

It’s not uncommon to have several miles of conveyor in the 

largest retail distribution centers. 

66 F e b r u a r y 2 0 1 0 / Modern

Conveyor technology 

As the materials handling 

industry emerges from a recession 

and looks to grow again, how are 

Modern readers planning to deploy 

conveyor technologies in the future 

and what are their purchase plans? 

To find out, we surveyed e-mail 

subscribers of Modern as well as a 

sample of recipients of our e-newsletters. 

We received answers 

from 269 qualified respondents, 

defined as a reader who buys or 

uses conveyor for their company. 

The respondents represented a 

range of companies, both large and 

small, with 26% reporting revenues 

of more than $500 million, 20% 

reporting revenues of more than 

$100 million and the remainder 

under $100 million. 

Respondents also represent a 

mix of manufacturers, distributors 

and warehouses associated with 

manufacturing. The breakdown is: 

• 62% of those planning to purchase 

new conveyor will use it 

in a manufacturing plant, 

• 40% will use it in a distribution 

center, and 

• 30% will use it in a warehouse. 

Here are the most important 

results. 

From belt to towline 

From belt to towline conveyors, the 

conveyor industry offers a diverse 

mix of products, and Modern’s 

readers employ them all (see chart 

for complete listing). 

• 80% are using belt conveyor. 

• 63% are using roller conveyor. 

• 62% are using accumulation 

conveyor. 

• 53% are using motor-driven 

roller conveyor. 

• 47% are using chain conveyor. 

While fewer readers have 

installed sortation systems, the 

mix among those who have is fairly 

evenly divided among the different 

speed offerings, measured in cartons 

per minute (cpm). 

• 26% are using medium speed 

sortation (50 to 150 cpm). 

• 24% are using high speed sortation 

(150 cpm and up). 

• 20% are using slow speed sortation 

(up to 50 cpm). 

When it comes to future conveyor 

purchases, the picture 

remains much the same for the 

next 18 months: 

• 60% plan to purchase belt 

conveyor. 

• 41% plan to purchase motordriven 

roller conveyor. 

• 40% plan to purchase roller 

conveyor. 

• 39% plan to purchase accumulation 

conveyor. 

• 30% plan to purchase chain 

conveyor. 

Planning for the future 

Caution seems to be the watchword 

when it comes to future 

investments in conveyor and sortation 

systems. With the economy 

beginning to grow again, a segment 

of Modern’s readers is planning 

to spend more (23%) or the same 

(30%) on conveyor over the next 18 

months than they spent in the last 

12 months. Another 22% are taking 

a wait-and-see attitude before 

planning any future investments. 

And, those investments may be 

modest. Sixty-one percent report 

that they will spend $100,000 or 

less including 37% who say they 

PHOTOGRAPHY BY NAME 

Modern Materials Handling / F e b r u a r y 2 0 1 0 67


will spend less than $50,000 in 2011; 

only 14% expect to spend more than 

$1 million on conveyor technologies 

over the next 18 months. The median 

increase for those expecting to spend 

more is 20% over their 2010 budgets. 

On a more positive note, only 15% 

report that their overall materials handling 

budgets have been cut for 2011 

and only 8% say they will be spending 

less in 2011 than in 2010. 

That said, end users appear to be 

looking for growth in 2011, with 29% 

reporting that their conveyor purchases 

are part of a larger integrated system; 

meanwhile, 39% say they are purchasing 

the equipment for a new facility 

and 61% say their purchase is part of an 

expansion project. 

The majority of those purchases 

come directly from a conveyor manufacturer 

(54%) or conveyor distributor 

(39%). 

The same holds true when it comes 

to replacement or spare parts, with 

46% purchasing directly from a manufacturer 

or a manufacturer’s Web site 

(25%), while 38% purchase from their 

distributor or use their distributor’s 

Web site (16%). 

Which of the following types of conveyors 

are currently in use at your facility? 

Belt 

Roller 

Motion-driven roller 

Accumulation 

Gravity flow 

Chain 

Pallet 

Spiral 

Medium-speed sortation 

High-speed sortation 

Slat 

Low-speed sortation 

Power-and-free 

63% 

80% 

75% 

How is the economy impacting your spending on 

conveyors and/or conveyor parts and accessories? 

74% 

53% 

59% 

52% 

47% 

48% 

58% 

47% 

38% 

34% 

29% 

26% 

23% 

December 2010 

26% 

February 2010 

21% 

24% 

18% 

22% 

19% 

20% Note: 

25% 

Low Speed Sortation: up to 50 cpm 

20% Medium Speed Sortation: 50-150 cpm 

26% High Speed Sortation: 150 cpm and up 

Reliability counts 

Automated materials handling systems 

are mission critical. If a lift truck breaks 

down, another lift truck can pick up the 

slack. If a conveyor goes down, a facility 

may be down until that conveyor is 

back up and running. 

It comes as no surprise then that 

reliability was considered “very important” 

(72%) or “important” (25%) by 

more readers than any other attribute. 

The reputation of the supplier was a 

distant second, ranked as very important 

by just 39% of respondents. Price 

was also ranked as very important by 

39% of respondents. 

Conveyor users also appear to stick 

with the tried and true: Just 19% of our 

readers ranked leading edge technology 

as a very important factor in their 

buying decision, while 31% ranked it as 

relatively unimportant. 

When it comes to features, Modern’s 

readers value individually powered 

zones (57%); design flexibility (55%); 

low energy/power consumption (53%); 

low noise emission (48%); and intelligent 

conveying features (32%) in their 

systems. 

Will be spending about the same as 

as in 2010 on conveyors in 2011 

Will be spending more on conveyors in 2011 23% 

We are taking a 'wait-and-see' approach 

and not planning to invest at present 

Overall materials handling budget 

has been cut in 2011 

Will be allocating more on maintenance 10% 

Will be spending less on conveyors in 2011 8% 

15% 

22% 

30% 

Up and running 

Conveyor manufacturers, like lift truck 

providers, have been developing new 

maintenance programs for their customers. 

Still, Modern’s readers are 

mostly taking care of business when it 

comes to keeping their conveyor systems 

up and running. 

• 81% use their own crew for maintenance. 

• 8% have a service contract with an 

OEM/supplier. 


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©2011 Delta T Corporation dba the Big Ass Fan Company. All rights reserved.


How much do you estimate you will spend 

on conveyors and/or conveyor parts and 

accessories in the next 18 months? 

Approximately how much did you spend 

on conveyors and/or conveyor parts and 

accessories during the last 12 months? 

Average $ 

$263,000 

$321,000 

$255,000 

$297,000 

$300,000 

$261,000 

Median $ 

$80,000 

$92,000 

$76,000 

$81,000 

$75,000 

$55,000 

10% 

13% 

9% 

13% 

14% 

11% 

6% 

22% 

62% 

7% 

26% 

54% 

7% 

18% 

65% 

6% 

20% 

61% 

7% 

18% 

61% 

7% 

18% 

64% 

$1 million + 

$500K-$999 

$100K-$499 

A SPECIAL SUPPLEMENT TO: 

WAREHOUSE & DC 

Crossdock fuels 

by banking on a combination of crossdocking and flow-through distribution to rapidly 

provide its customers with the latest fashions at affordable prices, the retailer has 

emerged as a force to be reckoned with in a highly competitive retail landscape. 

BY maiDa napoLitano, CONTRIBUTING EDITOR 

There’s no wasting time at 

Dots. This Ohio-based 

fashion retailer uses a 

unique sourcing model to 

quickly interpret the latest 

fashion trends into 

everyday-wear apparel for women. And 

because what’s hot today may not be hot 

tomorrow, the retailer’s distribution team 

needs to immediately dispatch these latest 

looks from its suppliers to more than 

400 stores within a 26-state radius—and 

do it in a flash. 

How do they make this happen? Lisa 

Akey, Dots’ divisional vice president of 

distribution and lead project manager 

of the company’s new, state-of-the-art, 

193,000-square-foot facility in Glenwillow, 

Ohio, shares her secret: “At the end 

of the day, we have almost nothing that 

stays in the building. And the rest that 

does doesn’t stay long.” 

Once received, 20% of Dots’ volume is 

automatically crossdocked to shipping— 

sometimes in as little as 6 minutes—via a 

network of conveyors and conveyor sortation 

systems. Within 24 hours, the other 

70% has been diverted to two high-speed 

unit sorters that flow-through bulk merchandise 

to individual stores, while the 

remaining 10% of mostly basic, non-seasonal 

items, goes into storage for future 

replenishment. 

By banking on a combination of crossdocking 

and flow-through distribution 

to rapidly provide its customers with the 

latest fashions at affordable prices, Dots 

has emerged as a solid force in a highly 

competitive retail landscape. Over the 

next few pages, we’ll learn how Akey 

and the Dots logistics team have put this 

time-tested distribution method to work 

to keep the retailer one step ahead in a 

challenging and fickle market. 

growing pains 

Since the late 1980s, Dots has been distributing 

merchandise to its stores from 

a manual, more conventional facility, 3 

miles from its current location. Although 

this older facility afforded the retailer 

many functional years, by 2005, much 

of the equipment was nearing the end of 

its life, putting limitations on operational 

growth and efficiency. In fact, it took this 

previous DC three to four days to get a 

store order out the door. Vendors communicated 

via faxes and e-mails, and there 

was no receiving sorter. All carton-labeling 

from receiving to shipping was manually 

applied. 

When you boil it down, the company 

actually had been manually crossdocking 

for years—just nowhere near as fast 

and as efficient as they’re doing it now in 

the new DC. “Our previous system had 

no EDI (electronic data interchange) 

and limited, outdated automation that 

restricted our throughput speed and 

capacity,” recalls Akey. “There was a lot 

of double and triple handling just to get 

orders out the door.” 

With only one crossdock-capable 

door, many crossdock orders would be 

unloaded, then staged, then put in a 

queue before actually getting processed— 

a clear departure from cross docking’s 

“expedite immediately” philosophy. 

To distribute bulk apparel to the 

individual stores, Dots was using a 

10-year-old, put-to-light system that 

they had simply outgrown. “To support 

the volume demand, we had to go to 

extended shifts and work a lot of overtime,” 

notes Akey. 

The clock was also ticking because 

the put-to-light system’s capacity was 

limited to 500 stores. In 2005, they 

were already sitting at 350 stores and 

growing at a rate of 40 new stores per 

year. “These outdated systems and their 

inability to support future store growth 

is what ultimately pushed us to move 

forward with the process of designing a 

new distribution system,” says Akey. 

pLanning anD eXeCution 

So in March 2006, Akey began the 

process of selecting a consulting firm 

that could help Dots design a new distribution 

system. After three months of 

extensive interviews, site visits, and reference 

checks, Dots decided to partner 

with California-based SDI Industries, 

a systems integrator and solutions provider 

that had extensive experience in 

the fashion retail industry. To aid in the 

analysis and establish best practices 

benchmarking, SDI brought in another 

California-based consultant, Dennis 

Green from Green & Associates. 

For several months, the team collected 

data; audited current processes 

from source, to DC, to store; and anas72 

F e b r u a r y 2 0 1 1 / Modern Materials Handling mmh.com

growth at Dots 

lyzed business projections before nailing 

down the final detailed system design 

in November 2006. “The process was 

slow and tedious,” says Akey. “However, 

it was critical to define every nuance of 

the system, including all system specifications 

and software interfaces. Without 

this level of detail, a successful implementation 

could not have happened.” 

In May 2007, after a lengthy study 

of the present building and available 

alternative sites, Dots made the decision 

to build a completely new office 

and distribution center in Glenwillow, 

Ohio. In February 2008, groundbreaking 

took place and SDI was selected to 

install and implement the entire distribution 

system. 

In September 2008, with only the 

floor and the building shell in place, 

SDI began mechanical installation 

of the new distribution system. “The 

schedule was aggressive and followed 

closely behind the actual construction 

of our new building,” says Akey. 

By January 2009, SDI completed 

the installation of the equipment and 

immediately started hands-on training. 

“Because the unit sorters were perhaps 

the biggest change from the old system, 

we arranged for Dots to send their people 

to our other clients’ sites to literally 

work on their unit sorters,” says Steve 

Lisa Akey, divisional vice 

president of distribution, Dots, 

Steve Haskell, vice president 

and lead implementation 

manager, SDI 

Photographs by Roger Mastroianni 

mmh.com 

Modern Materials Handling / F e b r u a r y 2 0 1 1 S73

Special Supplement: Warehouse & DC 

1 2 3 

Haskell, SDI’s vice president and lead 

implementation manager. From January 

to April, SDI’s software team was 

also onsite to train Dots personnel and 

offer systems support. 

Because Dots did not really have a 

true warehouse management system 

(WMS), “this became a more involved, 

all-encompassing warehouse control 

system (WCS) and software project on 

our end,” adds Haskell. “The new WCS 

is totally tailored to match Dots’ systems 

with almost no changes on their 

side.” Transition to the new DC was 

complete by May 2009. 

Keys to suCCess 

According to Akey, installation of the 

automated equipment and software 

was only half the battle. The true key 

to a successful crossdock is the automated 

exchange of information through 

EDI between Dots and its many vendors 

even before the product physically 

arrives at the receiving door. 

Dots’ IT department had the unenviable 

task of getting its many vendors 

and suppliers onboard with EDI. “The 

EDI team has now transitioned a significant 

portion of our vendors to EDI, 

representing about 50% of the units 

processed with the goal of impacting 

80% of units this year,” reports Akey. 

Dots also dedicated a substantial 

amount of resources on extensive training 

and building job aids for its internal 

allocation and merchant teams. “These 

job aids guide the vendors to identify 

the best way to pack a purchase order 

(PO) based on a category and allocation 

plan,” says Akey. “Everything 

begins with the correct PO. If the PO 

is not written correctly or if the vendor 

ASN (automated ship notice) does not 

match, everything stops.” 

Opportunities to build crossdock 

cartons are also identified at this point. 

Akey lists denim, fall sweaters, outerwear, 

footwear, and other bulky items 

that tend to quickly fill store cartons as 

naturals for crossdocking. 

How the Dots system works 

The new operation is a blend of the 

most advanced conveyor and mechanical 

technology with the latest systems in 

information processing and control software. 

It is this combination of hardware 

and software that allows the retailer to 

achieve its goal of same-day distribution. 

A vendor ASN is received either via 

EDI or e-mail 24 hours in advance of the 

physical merchandise arriving. Once allocations 

are received, cartons are unloaded 

onto one of six receiving conveyors. They 

flow easily through the system with 

either the vendor-applied License Plate 

Number (LPN) or, in the case of manual 

ASNs, LPNs that have been printed 

onsite and have been manually applied. 

Cartons then flow quickly to the merge 

and shipping sorter where they can be 

6 7 8 

S74 F e b r u a r y 2 0 1 1 / Modern Materials Handling mmh.com

4 5 

diverted to one of 14 possible destinations: 

eight shipping lanes, one automated printand-apply 

lane, two unit sorter induction 

lanes, one VAS lane, one new store/storage 

lane, and one no-read lane. 

In the old system, Dots had been 

crossdocking more—up to 45% of its 

unit volume. With the new unit sorters 

in place, however, it became a strategic 

decision to more precisely flow merchandise 

to stores based on specific 

needs up until the point of allocation 

while still creating an efficient, cost 

effective outbound carton. 

“As we’ve done more analysis of 

each store and its sales history, we’re 

replenishing only what that store actually 

needs,” says Akey. “That may sometimes 

be less than a crossdock carton.” 

As a result, there is now a smaller ratio 

of units being crossdocked, from 45% 

in 2005 down to 20% in 2010, and 

more units (up to 80%) being processed 

through the unit sorter. 

Reaping the benefits 

This shift to automation has predictably 

increased Dots’ capacity by leaps 

and bounds, allowing the retailer to 

now easily support up to 700 stores 

within their current footprint. Volume 

throughput from the two unit sorters 

almost triples that of the previous putto-light 

system (5,500 vs. 1,900 units/ 

hour). The new shipping sorter now 

processes up to 80 cartons per minute 

(cpm), more than three times the old 

sorter that operated at 25 cpm. 

Productivity increased 20% versus 

2008 statistics with a 30% increase 

planned for 2011. The company also 

achieved a 20% reduction in labor 

costs. “For the past few years, suppliers 

have been forced to pick-pack for 

retailers at supposedly no cost,” notes 

Haskell. “Dots now has the flexibility 

to call on vendors that can’t or won’t do 

it, while keeping control on distribution 

costs and quality.” 

With minimal storage requirements 

and only 70,000 of the 145,000 square 

feet of DC space in active use, there’s 

substantial room for expansion or 

special projects. “At some point, the 

ultimate plan is to position ourselves 

to go to e-commerce,” says Akey. For 

now the retailer continues to work on 

supply chain efficiencies to maximize 

their system. 

What’s been critical to this project’s 

success? “Choosing the right integrator,” 

adds Akey. “One who is committed 

to you and who will provide you with 

great ideas and solutions.” Second, she 

says, is “planning and more planning; 

training and more training.” 

Haskell agrees. “When you go automated 

and you tie the front door to 

the back door in 6 minutes, you better 

know how to run it.” M 

Maida Napolitano is a Contributing 

Editor to Modern Materials Handling. 

9 

1. Workers unload cartons from trailer. 

2. Inbound cartons travel to merge. 3. 

After merge, crossdock cartons enter printand-apply 

stations, then are conveyed to 

shipping lanes. 4. After merge, cartons for 

store distribution get processed at the unit 

sorters. 5. At unit sorters, individual pieces 

travel on trays and get sorted to specific store 

cartons. 6. When store carton is full, worker 

closes carton. 7. Worker scans label on store 

carton then pushes carton to center takeaway 

conveyor. 8. Store carton travels to shipping 

lanes. 9. Crossdock and store cartons are 

diverted to one of eight shipping lanes. 

mmh.com 

Modern Materials Handling / F e b r u a r y 2 0 1 1 S75

FOCUS ON Lift trucks 

AC-powered trucks conserve, 

regenerate power for longer run times 

Offered in capacities from 4,000 to 6,500 pounds— 

including a new 5,000-pound model—the 8-Series fourwheel 

lift trucks for indoor handling are AC-powered 

with subsystems that conserve or regenerate power 

to maximize operational productivity between battery 

charges. The motor compensates for battery depletion 

for longer run times and consistent power output. 

Regenerative braking, coast control, and plug-and-foot 

braking extend run times and prolong brake component 

life. To reduce maintenance costs, there are no motor 

brushes, springs, 

commutator or 

wearable parts to 

service and replace. 

Operator ergonomics 

is enhanced with 

expanded leg room, 

four-way adjustable 

suspension seat, joystick 

hydraulic controls, 

multifunction 

digital display and ample visibility from the driver’s seat. 

Toyota Material Handling U.S.A., 800-226-0009, www. 

toyotaforklift.com. 

Stand-up counterbalanced 

truck is 100% AC-powered 

The platinum SCX series of stand-up counterbalanced 

trucks is offered in three lifting 

capacities up to 4,000 pounds. Fully 

AC-powered, the vehicles feature two independently 

controlled drive motors and drive 

units integrated with a continuous feedback 

system for faster acceleration and high travel 

speeds, both loaded and empty. The system 

also conserves energy to extend battery run 

times with standard auto-power off and regenerative braking. Other 

features include automatic self-check, smart LCD meter panel with 

on-board diagnostics, standard thermal protection on motors and controllers, 

and rugged steel chassis and enhanced mast. Nissan Forklift, 

815-568-0061, www.nissanforklift.com. 

VNA truck lifts 4,000 pounds up to 

360 inches high 

Capable of handling up to 4,000 pounds, the four-wheel B40VAC 

very narrow aisle truck features rear-wheel drive, 15% gradeability, 

fast travel speeds and enhanced power efficiency. A 32-inch wide 

front axle as well as a slim line, three-stage mast enable the truck to 

stack loads with footprints measuring 48 x 40 inches from 72-inch 

aisles. Loads can be lifted up to 360 inches high. Bendi/Landoll, 

800-428-5855, www.landoll.com/mhp/bendi_electric. 

SUPPORT 

Cubic Designs makes it 

easy to integrate a singleor 

multi-level platform 

into your valuable project. 

We offer professional 

engineering, manufacturing, 

and installation to support 

you at every level. 

© 2011 Cubic Designs 

at every level. 

the perfect fit 

VISIT US 

at ProMat, booth #1247 

800.826.7061 www.cubicdesigns.com 

goodbye to exposed belts 

goodbye to grooved rollers 

hello 

hello to ShaftDriveTM ! 

Conroll’s NEW 

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System 

Visit us at 

ProMat Booth 

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To learn more about the 

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system, 

call us at 877-805-4292 or 

visit us on the Web. 

• Safe, low-voltage 24VDC 

brushless motors 

• Perfect for transport and zero 

pressure accumulation 

• Accommodates virtually any roller 

or wheel configuration 

• IP66 rated sanitary washdown 

version available 

• Pre-assembled complete drive 

elements simplify assembly 

• Fully assembled conveyor modules 

available for OEMs 

www.conroll.com Conroll Corp. | 910-202-4292 | Fax: 910-202-4280 

mmh.com MODERN MATERIALS HANDLING / F E B R U A R Y 2 0 1 1 77 

mmh201102_conrollQTR.indd 1 

1/4/2011 10:22:41 AM

ww.zoneworks.com. 

ce, a series programming 

U.S. Patent Pending of low-cost platform, 

Featuring automatic and up to 

a stabilized temsinc.com. 

400 different pre-programmed recipes. 

shelf system 

american-newlong, 317-787-9421, www.american-newlong.com. 

with high storage density at an affordable 

price, the motorized vertical pan 

carousel offers storage and retrieval of 

Belts inventory with push-button control. The 

system delivers inventory to the operator, 

yielding retrieval time savings up 

to 90%. Included standard are lifetime 

sealed bearings, shielded motors, security 

keypad, one-touch forward/reverse, 

wire mesh guarding and obstruction 

detectors. Vidir Machine, 800-210-0141, www.vidir. 

com, Booth 3018. 

etter than 

ifetime 

arranty 

e others fail. 

nbreakable. 

loads. 

capacity. 

ools 

. 

614-777-0295 

ww.durabelt.com 

S ls HANDLING 


ANDLING 

Software directs, analyzes 

paperless picking activity 

Executives, managers and supervisors can easily view 

pick rate productivity, accuracy and throughput with 

the version 6.0 release of LP dashboard. 

The software displays realtime, 

updated key performance 

indicators with drill-down granularity 

for facility, area, zone and employeelevel 

views. Featuring a rich graphical 

interface with drag-and-drop 

widgets for custom template views of performance 

data, the system offers an automatic slide-show 

style display of multiple, user-configured templates. 

Lightning Pick Technologies, 262-250-2143, www. 

lightningpick.com, Booth 1543. 

mmh.com 

mmh.com 

10/12/10 7/6/10 1:56 1:59 PM 

3/10/2010 3:49:09 PM 

4/8/2010 11:34:55 AM 

3-wheel counterbalanced 

trucks maximize operator 

comfort 

To enhance ergonomics, the 4150 and 

4250 stand-up counterbalanced lift trucks 

incorporate greater visibility, increased 

maneuverability, a shorter head length, 

dual steer tires, and responsive suspension. 

Offered in load capacities from 

3,000 to 5,000 pounds, operator comfort 

is ensured by a smooth-ride suspension 

and cushioned floor mat that isolates 

operators from impact and vibration. The 

suspension adapts automatically to each 

operator’s weight 

and employs only 

nine parts for simple 

maintenance. 

The three-wheel 

trucks perform 

right-angle stacking 

maneuvers 

in less total area, 

with dual-steering 

that allows one 

wheel to counterrotate 

during 

turns for a 

shorter 

turn radius 

and reduced 

tire loading and steering friction. The 

Raymond Corp., 800-235-7200, www. 

raymondcorp.com. 

Motorized Storage & 

Retrieval Solutions 

10/6/10 4:00 PM 

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• Bar Stock • Spooled Products • Tire Storage 

• Print Cylinders • Rolled Goods • Parts Storage 

“Storage & Retrieval Solutions Since 1986” 

Contact Us Toll Free at 1-800-210-0141 

or visit us online at www.vidir.com 

Maneuverable tuggers 

pull up to 15,400 pounds 

Offering maximum strength and durability, 

the CTX 40 and CTX 70 utility 

tuggers include gear type steering for 

long-term reliability with easy maneuverability 

enhanced by headlights and 

turn signals. The AC-powered vehicles 

pull 8,800 and 15,400 pounds, respectively, 

and include utility cargo areas 

capable of carrying up to 400 pounds. 

For operator comfort, a full suspension 

seat is included. When the operator 

leaves the seat, the truck is disabled. 

When the key switch is turned on, the 

controller completes an auto diagnostic 

check. To prevent the tugger from 

rolling down inclines when stopped 

or started on a ramp, an anti-rollback 

function is included. Clark Material 

Handling, 866-252-5275, www. 

clarkmhc.com. 



Heavy-duty trucks protect operator 

with 3 cab styles 

A line of 8,000- to 12,000-pound capacity internal combustion pneumatic 

tire lift trucks is ideal for heavy-duty applications. The vehicles 

have a choice of three-panel cab styles 

to protect operators from the elements. 

To improve uptime and lower 

maintenance costs in dusty or dirty 

applications, fully enclosed oil-cooled 

disc brakes may be specified. Options 

include attachments, foundry and 

brick protection and specialty tires 

for truck customization, extending 

equipment service life and minimizing 

product damage. Cat Lift 

Trucks, 800-228-5438, www.catlift.com. 

Cushion, pneumatic tire lift trucks 

For moderate-duty applications, the internal combustion S50CT cushion tire and 

H50CT pneumatic tire lift trucks include sealed electrical connectors, O-ring face 

seal fittings on the truck chassis, and durable transmissions. Intended to be costeffective, 

no-frills vehicles, the trucks deliver high fuel economy and operator comfort. 

Both models lift up to 

5,000 pounds and maneuver 

through tight spaces with 

an electronically controlled 

transmission for smooth 

direction changes. For optimal 

load positioning, an integral 

sideshifter is an option, 

while electronically controlled 

inching adjustments give the 

operator better positioning 

control. Extra foot space, 

adjustable tilting steer column 

and increased visibility 

enhance operator ergonomics. 

Hyster, 800-497-8371, 

www.hyster.com. 

Innovative 

Systems 

Solutions 


1-(877)-MECALUX

tive 

ck 

. 

u- 

lyows 

For 

s, 

ty 

x 

- 

20 x 14.25 inches and include optional lids to protect 

contents from dirt and damage. Molded Fiber Glass 

Tray Co., 800-458-6050, www.mfgtray.com. 

POWER TRANSMISSION-PART CONVEYING 

PYRATHANE ® BELTS 

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Samples available at little or no cost • Colors Available 

Very Clean in Operation • Eliminates Tensioning Devices 

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2/9/2010 1:05:37 PM 


Truck series lifts up to 19,000 pounds 

Offered with a choice of engines, the Veracitor VX truck series 

features low fuel consumption, minimal noise, and reduced 

maintenance and operating costs. Both cushion and pneumatic 

tire classes are included. Capable of lifting capacities from 

3,000 to 19,000 pounds, the trucks employ a maintenance-free, 

built-in stability system. The durable, rugged powertrain incorporates 

computer-controlled engine and transmission, sturdy 

clutch packs, and strong gears 

and shafts. All transmissions have 

smooth electronic inching to cut 

maintenance costs by eliminating 

periodic adjustments. For 

maximum brake life, an auto 

decelerator system automatically 

slows the vehicles 

when the accelerator pedal 

is released. Yale Materials 

Handling, 800-233-9253, 

www.yale.com. 

AC-powered very-narrow-aisle truck 

with swing mast 

The AC-powered, three-wheel 

swing mast model SLT30AC 

very narrow aisle truck 

includes enhanced control and 

improved power efficiency. 

It is offered with a quad 

mast that rises to 272 inches. 

Capable of handling up to 

3,000 pounds, the vehicle may 

be equipped with an optional, 

affordable wire guidance system 

that is easy to set up and 

install. Drexel/Landoll, 800- 

428-5655, www.landoll.com/ 

mhp/drexel. 

Fuel cell powered stockpicker 

Capable of accommodating fuel cells, the SP 3500 stockpicker 

integrates a hydrogen level indicator on the dashboard display, 

plus programmable performance settings and advanced 

diagnostics for the fuel cell power unit. Operators receive 

an alert when the fuel cell hydrogen pressure reaches a predetermined 

level—between 2% and 25% of hydrogen remaining. 

Technicians can use the dashboard display to view fault 

codes, including the last event code, for maintenance and 

troubleshooting. Ideal for narrow-aisle applications, the truck 

can be used for pallet handling, picking at heights and transport. 

Crown Equipment, 419-629-2311, www.crown.com. 


Multi-directional reach trucks offer 

5 travel programs 

Multi-directional reach trucks for stacking and retrieval at high 

lift heights—or for transporting long loads up to 26.2 feet in 

narrow aisles—include electric all-wheel steering. The ETV 

Q series offers five travel programs, from modified standard 

travel to rotational travel and all-wheel parallel travel. The 

enhanced normal travel program steers the load wheels simultaneously 

with the drive tire. Other travel programs include 

360-degree steering, minimum 

turning radius and rapid 

direction change. Operator 

ergonomics are enhanced 

by a full-suspension comfort 

seat with adjustment features 

and automotive-style pedals. 

For maximum uptime, 

three-phase AC drive, lift and 

steering motors are maintenance-free 

without carbon 

brushes, brush springs or 

commutators. Jungheinrich, 

877-543-6757, www. 

jungheinrich.com. 

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modern 60 Seconds with... 

George Prest 

Title: Chief Operating Officer, 

the Material Handling Industry of 

America 

Location: Charlotte, N.C. 

Experience: 34 years in the 

materials handling and rack 

business 

primary focus: Prest’s 

responsibilities at MHIA include 

trade shows and industry events, 

membership meetings and 

statistical information 

Modern: After so many years 

working in the materials handling 

industry, what brought you to MHIA 

now? 

Prest: It was the perfect storm. As 

you’re probably aware, I’ve been 

on the Board of Governors of MHIA 

since 1996. Three years ago, when 

I sold Prest Rack, this opportunity 

wasn’t on the radar. But, through a 

set of circumstances, the position 

opened up. I’ve always had a passion 

for the industry, I’ve always wanted to 

do something to give back and this 

seemed like a good opportunity. 

Modern: What do you think have 

been the most important changes 

to the materials handling industry 

that you’ve observed over the 

years? 

Prest: The biggest change that I have 

seen has been the advances made 

in technology. My elevator speech— 

what I say when people ask me about 

our industry—is that the materials 

handling industry touches everything. 

What’s changing, and also what’s 

fascinating to me, is how our industry 

is broadening its reach. Historically, 

what we only worried about what 

happened inside the four walls of a 

factory or warehouse. 

Today, we are still inside the four 

walls, but we are also logistics and 

we are intermodal—we literally touch 

everything in the supply chain. That’s 

exciting. 

Modern: This is our ProMat 2011 

show preview issue. What should 

readers be looking for at this year’s 

ProMat? 

Prest: The ProMat pitch is simple: 

You’ll have everything from the 

traditional solutions to the cutting 

edge and everything in between. M 

To register for ProMat 2011, visit 

www.promatshow.com. 


TECTON HANDHELD COMPUTER 

PURPOSE-BUILT FOR THE WAREHOUSE 

Smarter and Faster. 

Prepare to Move Mountains. 

• PXA320 806MHz processor 

• 55 or 32 key backlit keypads 

• Natural handgrip ergonomics 

and removable pistol grip 

IP 65 

5FT 

6FT W/ BOOT 

VOICE 

READY 

-22°F 

www.lxe.com/tecton

New Avenger Vertical Carousel 

Small Parts, Items and Inventory Vertical Carousel 

AS/RS Built For Reliability & ROI… 

• Up to 10 Year Warranty 

on Some Models 

• Reduces Labor by up to 2/3 

• 45% Less Energy Consumption 

Designed for reliability and performance! Engineered to 

eliminate cascading arm failure by using a dual reinforced 

arms and forging assembly (patent pending). The number 

one historic failure point on vertical carousels is eliminated 

for performance and improved ROI (return on investment). 

New... number one failure point 

in Vertical Carousels is solved with 

patent pending arm assembly that 

eliminates cascading arm failure. 

Superior design... up 

to 10 year warranty 

available! 

Whisper quiet operation. 

The Avenger Vertical Carousel Difference: 

• Double reinforced arms and forging assembly 

(patent pending) 

• Modular construction 

• Dual work counter and built in label printer 

dispenser available 

• Interchangeable shelves/carriers 

• Flexible design to meet today and future needs 

• Full range of pick to light accessories 

• Full suite of inventory management software 

• Courtesy electric outlets available 

Available 

Height 

15’ 

25’ 

35’ 

Typical Floor Space Savings 

Elimated Bays 

of Shelving 

30-36 

58-66 

86-95 

Space 

Savings 

76% 

85% 

89% 

Emergency rotation 

over-ride 

TIC (Transaction Information 

Center) pick to light system. 

Single or optional dual level 

work counter available. 

Optional label 

printer holder. 

Booth# 4231 

SAPIENT 

A U T O M A T I O N 

The Intelligent Material Handling Company 

Call or Email For A FREE Space & Productivity Analysis Today! 

888-451-9711 | www.GetSapient.com | info@getsapie nt.com

Modern Materials Handling - February 2011

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