Automated System Allows Technicolor to Ship Billions of CDs and DVDs Annually

Technicolor is the world's largest manufacturer and distributor of Blue Ray Discs, DVDs, video games, and CDs, with an annual capacity of 2.1 billion units per year. The 650,000 sq. ft facility in Livonia, MI processes new releases for clients including Paramount, DreamWorks, Microsoft, Warner Brothers, and Walt Disney Pictures.

Technicolor needed to automate their current processes in order to provide better quality control, faster order turn around, and positive verification that all orders had shipped to their customers.


Key Technologies

  • 2 Accusort High Speed Unit Sorters and Automatic Print & Apply area
  • 38,000 sq. ft. of Steel Solutions Mezzanine
  • Over 5,000 ft. of conveyor including Empty Carton and Full Carton Conveyors, Sawtooth Merge, 8 Packout Stations, and Shoe Sorter
  • TGW Ermanco Narrow Belt Sorter that diverts to 40 gravity lanes
  • Human-Machine Interface (HMI)
  • Mettler-Toledo In-Line Weigh Scale

See the results

  • Bastian was able to meet the tight design and installation schedule
  • The new system was able to provide a controlled flow of boxed, completed orders and all material flow can now be tracked for accountability
  • Each the Accusort Scanners can sort 159 units per minute and can generate up to 30 cases of finished product per minute
  • The Print & Apply line handles up to 55 CPM while the Shipping Sorter will support a throughput rate of 90 CPM

Photos of our solution

  • technicolor-livoniami_1024x768_(1)

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