High Speed Full Case Fulfillment System

Conair is a leading manufacturer and distributor of health and beauty products and kitchen and electronic appliances. 

Bastian Solutions was selected to provide and install new warehouse automation at its distribution centers located in New Jersey and Arizona. The larger New Jersey facility is highlighted in this case study and consists of a new sortation conveyor system to automate wave picking processes that had been performed manually from order-picker trucks. In-line print-and-apply carton labeling systems were also integrated into the conveyor system to eliminate the manual application of shipping labels.


Key Technologies

  • Full case picking: deep-lane pallet-flow conveyors with brakes
  • Saw-tooth merge, belt-merge, high-speed belt curves
  • High-speed shoe sorter at 350 feet per minute
  • Parallel high-speed label print-and-apply machines for increased throughput
  • Fluid loading powered extendable conveyors for parcel shipment
  • Control System and Human Machine Interfaces (HMI)

See the results

  • Met the Christmas rush and eliminated all back orders 
  • High throughput, systematic process reduced handling 
  • Number of days to fulfill orders cut in half 
  • Number of retail shipping penalties virtually eliminated 
  • Order accuracy increased through automation and label verification scanning system 
  • ROI based on reduced manpower and handling costs

Photos of our solution

  • conair-eastwindsornj_800x6000CB76B2982D1F23A8E2F3E3F_(1)
  • conair960x540

Interested sortation conveyor systems? 
See more information on conveyor systems or contact us!