Top Material Handling Trends Shaping the Future of Manufacturing and Logistics

Artificial intelligence and other smart technologies help boost operational efficiency

Smart technologies such as robotics, automation, and artificial intelligence (AI) in material handling operations remain the leading trends for manufacturers, distributors, and warehouses in their quest to improve operational efficiency.

“Companies of all sizes in the manufacturing, warehouse and distribution sectors are realizing that they need new technologies and sustainable options to remain competitive in an increasingly demanding marketplace,” said Alec Fitzgerald, Digital Marketing Supervisor for Ultimation.

 

Based on interactions with our customers, we see an interest in these five material handling trends:

 

  1. Enhancing human labor capacity with automation and robotics. Companies continue to automate some material handling tasks to address the ongoing skilled labor shortage in the manufacturing, distribution, and warehouse sectors. Automated processes offer improved efficiency and accuracy of material movement and fulfillment processes. For example, robots are being used to move material through a facility, retrieve products, or take items on or off a conveyor belt. It’s also becoming more common for robots and employees to work side by side, with the robots handling tasks that are repetitive, involve heavy lifting, or are otherwise unsafe for humans.

 

  1. Harnessing data for operational efficiencies. Companies are becoming more aware that the data produced by machines and equipment can help them resolve their biggest material handling challenges. Internet of Things (IoT) technology brings together the data and information locked inside sensors, radio frequency identification (RFID) chips and other sources and gives supply chain managers new insights into their operations. For example, real-time collection of product and material data such as condition, load capacity, temperature, and other metrics can be used for better decision-making to improve process flows, minimize idle times, and reduce cost. “Smart” systems such as barcoding technologies that integrate with existing Enterprise Resource Planning (ERP) and inventory systems are also being used to streamline processes and gain efficiencies. 

 

  1. Working smarter with machine learning and artificial intelligence (AI). Artificial Intelligence continues to transform supply chain operations with a dizzying array of possibilities. Companies with robust digitalization strategies leverage AI and machine learning to consistently improve their productivity. Both AI and machine learning automate a variety of manual processes involving data and decision making. For example, they can monitor equipment data to determine the optimal time to perform maintenance or study a facility’s energy use patterns to maximize efficiency. In the new year, expect material handling leaders to prioritize technologies that increase fulfillment accuracy, streamline inventory management, monitor equipment performance and optimize warehouse space. 

 

  1. Moving toward electrification and sustainability. Electrification isn’t just happening in the auto industry. It’s also a growing trend in material handling as companies convert older conveyor technology into more sustainable electronic options. For example, legacy conveyor systems that run constantly are being replaced with alternatives that only use electricity when they are actively moving cargo. Lightweighting is another trend rooted in sustainability, which involves swapping out heavier materials for lighter alternatives that enhance system efficiency. Additive manufacturing, also known as 3D printing, can also play a role in sustainable operations. It can reduce waste and reduce energy usage when compared to traditional manufacturing. 

 

  1. Maximizing facility footprints. Companies look to consistently optimize their facility footprints to improve the process flow, operational efficiency, and flexibility. Conveyor systems with modular designs make planning simple if changes or expansions are required. Mix-and-match solutions across several different conveyor types, such as roller conveyors, belted conveyors, and key sorting elements, can easily be combined for a customized solution. Lifters and overhead conveyor systems are an affordable, effective solution that can be deployed to take advantage of otherwise unused vertical space. 

 

We offer a number of products and services that help industrial companies improve the productivity and efficiency of their material handling operations.  

Shop our online store or speak to a specialist today for a custom solution.

Ultimation Industries Introduces New Controls Package to Optimize Heavy-Duty Chain-Driven Live Roller Conveyors

Integration can be done without specialized engineering or customization when using Ultimation HD CDLR conveyors

ROSEVILLE, Mich. (Oct. 22, 2024) – Ultimation Industries’ new controls package for Chain-Driven Live Roller (CDLR) conveyors helps manufacturers, distribution centers and others move heavy materials such as pallets, racks or industrial containers without the need for customization. Controls packages manage the speed, direction and buffering of items on a conveyor to optimize productivity.

 

“In the past, integrating controls into heavy-duty conveyor systems required specialized engineering expertise,” said Kali Wahrman, general manager for Ultimation. “We’ve developed our new controls package to work seamlessly with our CDLRs without the need for customization. It is also available online for quick delivery.”

Chain Driven Live Roller Conveyor Controls Package with VFD

Ultimation is an MCE company that solves productivity challenges with special purpose machinery and industrial automation equipment systems as well as direct-to-consumer solutions for a broad range of end-markets, including energy, automotive, logistics and vertical farming.

Ultimation’s new CDLR controls package offers both 120V and 480V AC input power options. It includes a gear motor controlled by a Lenze Variable Frequency Drive (VFD) for speed adjustment and frequency inversion. The E-STOP is hardwired to the safe torque off (STO) component on the VFD for immediate emergency shutdown.

CDLR Control Package with VFD

Here’s how the new CDLR controls package works:

  • Dual photoeyes detect parts entering the system, and check for any parts positioned at the end of the conveyor.
  • If there are no parts detected at the end of the conveyor when a part enters the system, it will advance the part to the end of the conveyor.
  • If there are additional conveyor segments connected downstream, the controls check for parts in the following position.
  • The parts will follow the same process for any remaining conveyor segments, until reaching the final conveyor zone.
  • The system will wait for the push button or additional photoeye signal to advance parts from the final conveyor zone.

 

The controls package can be added as an option to an Ultimation CDLR conveyor system or purchased separately.

For more information about Ultimation Industries’ automation equipment systems as well as direct-to-consumer quick-ship conveyor solutions, visit https://www.ultimationinc.com.

Success Stories: How Hobbyists Work with Ultimation

Some of the best ideas for using Ultimation products come from our customers. Check out the latest stories that offer creative ways to get products, raw materials—and even toolboxes!—from Point A to Point B.

Light-duty conveyor makes DIY projects easier

Light-Duty Gravity Conveyor Infeed DIY Woodworking

Ultimation’s Light-Duty Gravity Conveyor is a hit with DIY woodworkers. One customer who gives it five out of five stars says:

“Great help in feeding my table saw. Great value for the money. Highly recommended.” Another customer writes: “Great set of rollers! Smooth rolling action, very easy to set up…I am using them on a bandsaw and rolling steel into place is super easy.”

Despite its heavy-duty construction, Ultimation’s Light-Duty Conveyor weighs in at just 30 pounds. It has a length of 3 feet and an overall width of 12 inches (measured from outside of frame to outside of frame) and 10-inch between frames to accommodate a wide range of projects. The 1.5-inch diameter steel rollers are constructed of galvanized steel withstanding loads of up to 540 pounds when the conveyor is fully supported.

“Wish I’d found this Roller Stand Conveyor Set earlier!”

Gravity Conveyor with Legs 24"W x 3'L 6" centers galvanized steel rollers

Ultimation’s Roller Stand Conveyor Set may be the ultimate in workshop support.

“Boy, I wish I’d found them earlier,” says one customer, who uses the conveyor for outfeed tables for a drum sander, planer and table saw.

The set includes a gravity roller conveyor and two H-Style Support Legs, with a substantial 210-pound capacity and adjustable height from 23″ to 38-1/4″. The top of the legs are equipped with pivot plates that allow one end of the conveyor to be set higher than the other.

Another customer says: “I’m using them to support plywood as I push it through a table saw.”

“Very high quality,” writes another reviewer. “Rollers and hardware and excellent. This was produced for production use. Not just home owner do it yourself workshops.”

Keep tool cases (and everything else!) rolling

SKW-001 Top view group Skate Wheel

Our online store carries replacement parts as well as conveyor systems. One example is our line of Conveyor Skate Wheels, which are available in packs of 10, 50, 100, or 1,000, and cater to a variety of needs. One customer writes: “Great purchase! I used them to replace the wheels on my rolling tool case.”

Made of heavy-duty, zinc-plated steel, these durable wheels can support up to 50 pounds each. The pre-lubricated, sealed bearings block dust and dirt from entering. Designed for one million revolutions at full load, the wheels offer exceptional performance and longevity.

“These were absolutely perfect for my attic hoist project,” writes another customer. “The materials seem excellent. Ten out of 10 wheels were flawless, so quality control is good. I’m very pleased with my purchase.”

 

These are just a few examples of the many products available as part of Ultimation’s product line! Visit our online store for more information.

Jorge Giordanelli Promoted in Ultimation’s Leadership Transition

Jorge Giordanelli will take over from Richard Canny who is retiring

ROSEVILLE, Mich. (May 30, 2024) – Ultimation’s leadership transition as part of the MCE group of companies has entered its next phase with the recent promotion of Jorge Giordanelli, who will succeed Richard Canny. The leadership transition process has been underway since MCE’s acquisition of Ultimation in 2023.

“I am delighted to announce that Jorge Giordanelli has been appointed General Manager of Ultimation” said Patrick Dunn, VP/GM of Automation Products at MCE. “Jorge brings with him a wealth of experience, having had a successful career at General Motors in Latin America before joining Ultimation. Since joining our team, Jorge has demonstrated exceptional leadership skills and a deep understanding of our industry. I have full confidence that he will continue to lead Ultimation to even greater heights.”

Jorge succeeds Richard Canny, who will be retiring on May 31st after dedicating 12 years to the company’s development.

“Richard and his wife Jackie have played pivotal roles in shaping Ultimation into the successful organization it is today, and we are immensely grateful for their contributions. Even as Richard embarks on this new chapter, he will continue to support Ultimation as a consultant and MCE shareholder, ensuring a smooth transition for the leadership team. We extend our warmest wishes to Richard for a fulfilling retirement.”

 

Richard Canny (on left) with Jorge Giordanelli

 

Please join us in congratulating Jorge on his well-deserved promotion and in wishing Richard all the best for his retirement. The team at Ultimation is immensely grateful for the loyalty and support of our valued customers, suppliers, employees and business partners.

 

 

New Line of Interroll Conveyors from Ultimation Industries Helps Courier, Express and Parcel Companies Increase Distribution Capacity

Flexible modular systems adapt to a variety of needs and applications

ROSEVILLE, Mich. (Mar. 29, 2024) – Courier, Express and Parcel (CEP) companies that need to increase their distribution network capacity can now access a full line of Interroll® modular, sorting and pallet conveyor systems from Ultimation Industries, an MCE company. Ultimation is one of the leading distributors for Interroll USA and meets the strict requirements for technical and commercial capability for the Rolling on Interroll® (ROI) distributor program.

The new line includes a High Performance Conveyor Platform (HPP) for high throughput applications; a versatile Modular Pallet Conveyor Platform (MPP) solution for handling pallets; and a Modular Conveyor Platform (MCP) that offers mix-and-match solutions across several different conveyor types.

“Ultimation’s new line of Interroll platforms for the CEP industry is infinitely customizable and scalable for each client’s specific needs,” said Kali Wahrman, general manager of E-commerce for Ultimation. “Their modular configuration, variety of options and standard sizing makes the installation process quick and easy.”

MPP Modular Pallet Conveyor Interroll System

The new systems include:

  • High Performance Conveyor Platform (HPP) – This platform is the solution to situations where high throughput and reliability is required from a sorting conveyor, as well as applications where decline and incline conveyors are needed. The HPP enables a huge range of configurations, including the MultiBelt Switch, 2-in-1 Merge and many others. It also includes an intelligent diverter module that can be used as an autonomous mini sorter or intelligent diverter module for sorting when used in conjunction with other sorter systems.
  • Modular Conveyor Platform (MCP) – Interroll’s Modular Conveyor Platform offers mix-and-match solutions across several different conveyor types: 24V roller conveyors, 400V roller conveyors, belted conveyors, and key sorting elements. Each pre-assembled module in the MCP series comes in three standard widths to create the most efficient solution for the conveying task. Distributors can use DC RollerDrives in these systems to implement Zero Pressure Accumulation (ZPA) conveying or use the DC drives in conjunction with roller conveyors with 400V flat belt drives for higher performance. The modular concept of the MCP systems makes planning simple if changes or expansions to the system are required.
  • Modular Pallet Conveyor Platform (MPP) – Interroll’s MPP includes several different modules that are all specifically engineered for handling pallets. From infeed conveyors and turntables to transfers and stacker cranes, the MPP series has many different options designed to increase efficiency. It includes several different modular section options to minimize transportation times between production and picking areas, or goods receipt and goods issue or storage, such as infeed conveyors, roller conveyors, chain conveyors, transfers, turntables, and more. There is also a wide range of accessories available for the MPP series including end stops, feeding chutes, side guides, sensor holders and supports.

Interroll High Performance Conveyor Platform HPP System Sorting Conveyors

Ultimation also designs, builds and integrates customized solutions from Interroll and Portec into a customer’s existing system. For more information, visit the Ultimation website at https://www.ultimationinc.com/.