Growing UP: How Conveyor Systems from Ultimation Industries Can Improve Vertical Farming Productivity

Solutions range from simple to sophisticated

ROSEVILLE, Mich. (Aug. 8, 2022)— Indoor farming is all about maximizing food production per acre, but growers who want to further increase yields should consider growing “up” with the help of conveyor technologies that make use of the available vertical space within a facility, according to Ultimation Industries. Ultimation is the leading direct-to-consumer conveyor manufacturer for the food processing, vertical farming, warehousing, delivery and other industries.

A “growing” industry

Indoor vertical farming is expected to grow to $9.7 billion worldwide by 2026 from $3.1 billion in 2021, due to higher yields when compared to conventional farming, its capacity for year-round crop production and advances in lighting and other technologies.

 

“Conveyors are one of the simplest and quickest productivity improvements a fast-growing business can implement and are especially suited to the vertical farming industry,” said Richard Canny, president of Ultimation. “Simple roller conveyors or overhead I-beam trolleys can have a payback of days or weeks, while larger custom-built systems often have payback periods of only 3-6 months.”

 

Ultimation is currently building the material handling system for what is believed to be the world’s largest indoor vertical farming facility.

Ultimation Industries - grow lettuce

Increasing indoor farming productivity

Perhaps the most obvious way conveyor technologies can help increase indoor farming productivity is by taking advantage of unused vertical space above a work area. Overhead conveyors can lift growing trays when they’re not being actively managed and bring them back to operator level for tending and harvesting, allowing more produce to be grown within the same footprint.

Conveyors can also help reduce the manual labor of carrying items by hand, quickly and safely transporting plants from point A to point B. According to Canny, systems can be engineered to seamlessly integrate with harvesting and packing equipment available through Ultimation’s expansive partner network.

Ultimation uses materials made of galvanized steel, zinc-plated materials and powder-coated frames which are approved for food-grade applications and are easily cleaned—another productivity savings for indoor farmers. Ultimation can also design systems for hanging towers and growth pods made of food-grade plastic when required.

Types of conveyors used in indoor farming

Different types of conveyor systems are typically used for different parts of the growing process, according to Canny. For example, the sections of the farms where plants are sitting still can use simple, standardized material handling systems. Vertical format conveyors such as hanging towers or horizontal formats such as growing trays can be customized to match the grower’s needs.

Once plants are grown, more sophisticated technologies like automated motorized conveyors and automatic storage and retrieval systems are needed to safely move produce to the harvesting area. The most commonly used industrial automation equipment for indoor farming are gravity roller, belt, and skate wheel or flow rail conveyors. These systems use the force of gravity to move the load, allowing the product to roll along the upper surface.

More recently, the technology used in larger vertical farming systems is including motorized and overhead conveyors that take advantage of the generally unused vertical space above the working area. Using curved sections or even lifters, they bring produce down to operator level and back up to higher elevations as needed.

Power and Free conveyors are the ultimate in space and volume optimization for vertical farming systems as they enable tight concentration of product in some areas while also enabling separation of the products for movement to processing areas.

 

“The best planned and best-run indoor farming facilities take into account the product’s growth cycle and will likely use a combination of a conveyor system designs to maximize productivity,” said Canny. “Our engineers understand the economics of indoor farming and can help growers design, build and implement material handling solutions that meet their needs and budget.”

 

For more information about using conveyors to maximize indoor farming productivity, visit https://www.ultimationinc.com/.

About Ultimation:

Ultimation Industries, LLC is the leading direct-to-consumer conveyor manufacturer serving the automotive, food processing, vertical farming, heavy equipment, warehousing, fulfillment and delivery industries. The company offers a line of proprietary automation systems and is also the largest integrator of Jervis Webb Conveyor Systems. Ultimation’s e-commerce channel sells Ultimation, Interroll, Itoh Denki, Jervis Webb, and a wide range of other conveyor equipment. Ultimation was named a 2022 Michigan 50 Companies to Watch by Michigan Celebrates Small Business. In 2020, Ultimation was recognized as one of Inc. 5000’s fastest growing private companies in America. Visit https://www.ultimationinc.com/ for the latest product information and news about Ultimation.

 

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For further information please contact:

Nancy Sarpolis for Ultimation Industries at nancy@scgmich.com.

Ultimation Recognized as Leading Jervis Webb Conveyor Systems Integrator for Third Time

Company has long history of selling the “gold standard” of conveyors for multiple industries

ROSEVILLE, Mich. (July 14, 2022)— Ultimation Industries, the leading direct-to-consumer conveyor manufacturer, was named the largest integrator of Jervis B. Webb conveyor systems for a third time during a recent event in Fort Lauderdale, Florida. Ultimation designs, builds and installs material handling equipment for the automotive, food processing, vertical farming, heavy equipment, warehousing, fulfilment and delivery industries. Jervis B. Webb Company is a subsidiary of Daifuku North America Holding Company.

 

“Whether it’s a multi-million-dollar power and free conveyor system or a spare part that needs to ship today, Ultimation sells more than three times as many Webb products as any other integrator in the U.S. and Canada,” said Richard Canny, president of Ultimation. “We’re delighted to be at the top of the Webb rankings again for a third time.”

Jervis Webb Chain

Ultimation’s alliance with Jervis B. Webb began with their first major project in 2012. However, Webb’s history goes back much further. Young engineer Jervis Bennett Webb founded the company in 1919 with the idea of adapting the heavy chain conveyors used in the mining industry to suit Detroit’s fast-growing automobile industry. Webb’s breakthrough chain system was different from other conveyor chains: rivetless, stronger, forged and easily assembled. It could go from slack to tensioned quickly without breaking. In 1920, Webb realized that most existing floor-laid chains got in the way of the production process and got the idea of mounting the chain above the working area, and the overhead conveyor as we know it was born.

An overhead conveyor is generally used in a production facility to move parts from one location to another and take advantage of the generally unused vertical space above the working area. Using curved sections or when paired with elevators, they bring parts down to the level of operators and back up to higher elevations. Overhead conveyors can pass through production areas that humans can’t like through ovens and robot work cells.

 

“Installation of overhead conveyors takes time, so it’s all the more important to choose quality components and work with a trusted, experienced designer to make sure the system can meet the company’s needs for many years to come,” said Canny. “Jervis Webb is the gold standard for overhead conveyors and the genuine Webb product as designed and installed by Ultimation is going to achieve the long life that these conveyors can provide.”

 

For more information about Ultimation Industries and Jervis B. Webb conveyor solutions, visit https://www.ultimationinc.com/.

 

About Ultimation:

Ultimation Industries, LLC is the leading direct-to-consumer conveyor manufacturer serving the automotive, food processing, vertical farming, heavy equipment, warehousing, fulfillment and delivery industries. The company offers a line of proprietary automation systems and is also the largest integrator of Jervis Webb Conveyor Systems. Ultimation’s e-commerce channel sells Ultimation, Interroll, Itoh Denki, Jervis Webb, and a wide range of other conveyor equipment. Ultimation was named a 2022 Michigan 50 Companies to Watch by Michigan Celebrates Small Business. In 2020, Ultimation was recognized as one of Inc. 5000’s fastest growing private companies in America. Visit https://www.ultimationinc.com/ for the latest product information and news about Ultimation.

 

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For further information please contact:

Nancy Sarpolis for Ultimation Industries at nancy@scgmich.com.

Avoid These Five Mistakes When Choosing Food-grade Conveyors

Choosing the right conveyor system is a critical step in maintaining a safe food supply

Choosing the right material handling equipment for food manufacturing, processing and packaging is critical for maintaining safety, according to Ultimation Industries, the leading direct-to-consumer conveyor manufacturer for the food processing, vertical farming, warehousing, delivery and other industries. The World Health Organization estimates over 800 million people become ill after eating contaminated food and puts primary responsibility on producers for keeping food from becoming contaminated during the production and distribution process.

 

“Food-grade conveyors are one of the most important parts of the food and beverage industry because they transport raw ingredients, organic materials and other consumable goods within the facility and ultimately out to the consumer,” said Alec Fitzgerald, Digital Marketing Supervisor of Ultimation Industries

 

Choosing the right conveyor system is a critical step in maintaining a safe food supply. Unlike regular industrial conveyors, food and washdown material handling solutions must be constructed of sanitary and hygienic materials to meet rigorous safety standards and must be easy to clean, maintain and inspect.

 

Ultimation Food Grade Conveyor Dog Treats

 

Here are five mistakes to avoid when choosing conveyors for food-handling applications:

 

Mistake #1: Assuming all stainless steel is food-grade. Just because a conveyor is made from stainless steel doesn’t mean it meets food-grade requirements. SAE 304 stainless steel is the most common type of stainless steel used in the industry because it resists oxidization and corrosion, is easy to wipe clean and does not easily breed bacteria.

 

Mistake #2: Using food-grade stainless steel for everything. While stainless steel is the standard bearer for food-safe systems, different materials can be used safely depending upon the amount of contact the food has with a conveyor’s surface. For example, food moving along a belt conveyor is always in contact with the belt so the belt material needs to meet or exceed requirements for contact with the food. Frame and guarding materials, however, can often have different requirements if they are not in direct contact with food materials. The choices between stainless steel or lower grade materials can have a large impact on the cost of a conveyor system.

 

Mistake #3: Selecting the wrong type of conveyor for the job. There are a variety of conveyor types for food-related applications, but the most common is the belt conveyor. Belt conveyors are used throughout processing and packaging because they offer a smooth, continuous surface and are easy to clean. But based on the application, wire mesh, troughed and roller conveyors could also be good options. Food-grade wire mesh conveyors can withstand high and low temperatures and products are less likely to stick to them. Troughed conveyors keep bulk materials from spilling when conveying across long distances. Roller conveyors come in a variety of types and can be customized based on wash-down environment, specific temperatures and other variables.

 

Mistake #4: Choosing the wrong lubricants. Conveyors are always designed to ensure that any lubricants don’t get in direct contact with your product. But motors and bearings need lubricants or they will fail. Look for lubricants that meet the appropriate National Sanitation Foundation (NSF) grade. The ISO Standard 21469 is a voluntary standard that also provides more guidance in selecting lubricants.

 

Mistake #5: Not considering how the conveyor system will be cleaned. Cleanability is one of the most important factors for food-grade conveyor systems. To adhere to rigorous hygienic requirements, the conveyor should be designed to reduce the number of build-up points where residue can accumulate. When choosing a system, keep in mind whether the application requires dry, wet or sanitary cleanup. This will determine the type of rollers, frames, lubricants and electrical controls that should be used for optimal safety.

 

“Well-designed food and sanitary conveyors are a good investment and can provide many years of reliable service,” said Fitzgerald. “At Ultimation, we can help configure systems that meet safety requirements while creating lasting value.”

 

Ultimation Industries Joins the Qimarox System Partner Network

Maximizing vertical space helps manufacturers add capacity without costly facility expansions

ROSEVILLE, Mich. June 8, 2022 — A new partnership between Ultimation Industries, LLC and Netherlands-based Qimarox will help manufacturers and distributors move totes, cartons and pallets from one level to another while maximizing the vertical space in their facilities. Ultimation is the leading direct-to-consumer conveyor manufacturer serving the automotive, food processing, vertical farming, heavy equipment, warehousing, fulfillment and delivery industries. Qimarox is a leading manufacturer of components for material handling systems specializing in vertical sorters and conveyors.

“Manufacturers and distributors who are growing need cost-effective ways to get more productivity out of their existing facilities,” said Richard Canny, president of Ultimation Industries. “Better utilization of vertical space through lifters and overhead conveyor systems is an affordable, effective solution that can be deployed relatively quickly.”

Qimarox MK9 Vertical Pallet Conveyor

Ultimation is now part of the Qimarox System Partner network for the Americas and can design, build and install lifting solutions that integrate with existing material handling systems. Qimarox specializes in material handling systems that combine high performance with low costs. Their modular designs offer quick and easy installation and modification, with multifunctionality to complete a variety of different tasks. Qimarox solutions are also durable, requiring little maintenance and a high degree of operational availability.
Ultimation offers Qimarox lifters with a variety of carrier capabilities to handle multiple load weights and sizes:

  • ProRunner MK1 is a “discontinuous” vertical lifter because it moves from one level to another, stops, unloads and then returns. It can move cartons, tote boxes, trays, crates, boxes or bags weighing up to 160 pounds. The floor-mounted, self-supporting system requires no additional civil or integration engineering. The MK1 can achieve up to 360 cycles per hour to support high-volume distribution center conveyor process speeds. It has a small footprint that will fit into even the tightest layout.
  • ProRunner MK5 is a continuous vertical conveyor which can handle the needs of high-volume distribution centers. Due to its standardized modular design, the ProRunner MK5 is affordable and can achieve faster lead times than many custom engineering vertical conveyor solutions. Each carrier can handle 200 products per hour with the option to add up to 9 additional carriers to achieve 2,000 products per hour capacity. This unit is suitable for ascending and descending product flows at full load and has carriage sizes from 10″ x 10″ up to approximately 24″x 24″. The ProRunner MK5 can be paired with an optional gravity or MDR roller conveyor for infeed and outfeed.
  • Pallet Lift Prorunner MK9 is a very compact, space-efficient pallet or vertical conveyor lifter. The carriage can be equipped with a gravity roller conveyor or motor drive roller conveyor. Its 3,300-pounds weight capacity can handle pallets, racks, large cartons for appliances, vertical farming trays and other heavy and large loads. Cycle times are 60 cycles per hour or faster, depending on load and elevation change. It can be paired with an optional CDLR or powered MDR roller conveyor for infeed and outfeed.
  • Pallet Lift Prorunner MK10 moves pallets and other large and heavy loads that would otherwise require the design and build of a custom automation solution. This heavy-duty vertical conveyor lifter can handle loads of up to 4,400 pounds and can be used for pallets, racks, large cartons for appliances, vertical farming trays and other heavy and large loads. Cycle times are 60 cycles per hour or faster depending on load and elevation change. It can be paired with an optional CDLR or powered MDR roller conveyor for infeed and outfeed.

Watch a simulation of Qimarox lift conveyors in action in this video.

Qimarox recently introduced two new modules to the ProRunner family, both of which are available through Ultimation:

  • ProRunner 12 is a new high-speed, precision vertical reciprocating conveyor (VRC) that can move automated guided vehicles (AGV) to different levels. It can lift 440-660 lbs. at vertical speeds of nearly 4 to 6.5 feet per second, depending on load size.
  • ProRunner 15 combines the best of the PR1 and PR5 modules. While the PR1 can be used as a movable PR5 infeed conveyor for emptying of all buffering levels with the same conveyor, it needs a PR sorter for high-speed sorting in a vertical buffering system. The PR15 is simpler option for emptying buffer lanes in batch mode and reduces component costs more than 50% compared to PR MK5 Sorter for a typical five-level buffer system.

“With the incorporation of Ultimation to the Qimarox System Partner network, we are strengthening our presence in the American markets. Ultimation’s capability to deliver turnkey solutions with both standardized as well customized components, results in extremely added value to end users ensuring always the best automation solution for their process challenges,” said Pieter Hannessen, owner of Qimarox.

 

Qimarox and Ultimation are members of Rolling On Interroll® (ROI), a network of strategic partners through global material handling leader Interroll®.

“Partnering with Qimarox was a natural fit because we were already using their lifters as part of a custom conveyor and materials handling system for the world’s largest indoor vertical farming facility,” said Canny.

About Ultimation:

Ultimation Industries, LLC is the leading direct-to-consumer conveyor manufacturer serving the automotive, food processing, vertical farming, heavy equipment, warehousing, fulfillment and delivery industries. The company offers a line of proprietary automation systems and is also the largest integrator of Jervis Webb Conveyor Systems. Ultimation’s e-commerce channel sells Ultimation, Interroll, Itoh Denki, Jervis Webb, and a wide range of other conveyor equipment. Ultimation was named a 2022 Michigan 50 Companies to Watch by Michigan Celebrates Small Business. In 2020, Ultimation was recognized as one of Inc. 5000’s fastest growing private companies in America. Visit https://www.ultimationinc.com/ for the latest product information and news about Ultimation.

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For further information please contact:

Nancy Sarpolis for Ultimation Industries at nancy@scgmich.com.

New 3D Printer Expands Ultimation’s Design Capabilities

Ultimation Industries will soon have additional new 3D printing capabilities that will reduce the turnaround time for developing, testing and implementing prototypes of plastic parts. Ultimation won a new Photocentric LC Magna 3D Printer in a pitch contest hosted by Michigan Economic Development Corporation. Southfield-based CoreTechnologie provided the printer and related CAD software package.

Going for the prize

To win the printer, manufacturers had to submit an application as to how the industrial 3D printer would solve a labor, capacity or process challenge and support their business overall. Selected applicants were invited to make an in-person pitch during Automation Alley’s Integr8 Conference on May 10, 2022.

Tommaso Helwig, Ultimation’s engineering manager, made the winning pitch and said it will give the company more creative freedom to design parts in-house and will allow the company to implement changes at a fraction of the time allowed by outsourcing. “Prototypes can now be completed in hours or days rather than weeks,” he said.

Tommaso Helwig 3D printing

Good news for vertical farmers

The new 3D capabilities are especially good news for indoor vertical farmers, who rely on plastics to create food-safe environments for growing leafy greens, herbs, fruits and other produce. Indoor farms allow foods to be grown locally in areas where they may otherwise have been imported.

“Plastics are a very much part of a food safe environments and are an ever-growing part of our scope of work in indoor vertical farming,” said Tommaso. He added that within the last year, Ultimation has partnered with the largest indoor vertical farm to provide miles of a plastic drainage, flow rail, and conveyors to automate their farm.

Planting the seeds for a “green hub” in Detroit and South East Michigan

“Our goal is to connect Detroit’s rich manufacturing history and manufacturing network to this emerging market,” said Tommaso. “We are getting the chance to not only support innovative farmers who are challenging how we grow things every day, but also working to help solve one of the world’s largest problems: sustainability. With enough effort, Detroit can easily become one of the green hubs of this country.”

Ultimation believes that its evolving Agtech (Agricultural Technology) capabilities to provide full farm material handling and mechanical structure is a key enabler for future growth. The global vertical farming market was estimated to be $3.6 billion in 2021 and will increase to $17.6 billion by 2028.