Cornerstone designed the 4th generation standard PC based controller to replace the 1100AC2. The new CASI Core has some great features including solid state drive and Windows 7 OS. The optional CASI Core S model runs SQL Server and NEMA 4X washdown controller models are available.

See the new automation controller

It would seem strange to have “food” and “harsh environment” in the same sentence. However, when it comes to conveying food or other items that requires equipment to be washed, chemically sanitized, etc. the equipment itself must be able to withstand water, pressure, chemicals, etc.

The latest washdown conveyor from CASI is NEMA 4x rated; allowing the system to convey food or liquids as well and washed with water or cleaning agents.

CASI stainless steel conveyor uses all washdown components including frame, rollers, and belting material. Other NEMA 4X components with any conveyor system include touch screen PC controls, scanner/labeling housings, and checkweighers.

Call CASI for a quotation as each application may require different setup.

It seems that in designing a fulfillment system that optimizes putaway, picking, weighing, labeling, and sorting would solve nearly everything. There are many companies that manufacture or simply integrate systems based on third party products.

One challenge that can cause a lot of inefficiency in zone picking (pickers only pick to orders that come into their zone) is how to address items not in the flow rack. It is usually prohibitive to stock ‘everything’ or likely it is impossible to keep all things in all picking zones. Most companies opt to keep only the fast movers or top 80% of fast movers in their pick zones. What about the slower movers or items that are not in the flow rack zones?

Rather than send pickers out on a ‘per order’ basis when a slow mover is part of an order, there can be a temporary zone or zones set up that address all items not in the flow rack. A single picker can batch pick all orders at once that include item(s) not in the pick zones. Once items are picked, they are scanned to one of the temporary zones and the order is automatically released to the system once all items in that order are available for zone picking.

CASI has coined the term “Replenish to Order” or “RTO” as part the fulfillment process to eliminate costly time it takes to retrieve slow movers one order at a time. If you have a 500k Sq Ft warehouse, you can imagine how many trips back and forth are saved by having these items picked all at once.

Here is a case study that focuses on a fulfillment system using RTO.

It seems there is a machine or software solution out there for just about anything imaginable. In the material handling world this also rings true to the degree there is someone willing to buy such a solution or pay to have it custom built. One area that is often ignored even by some of the most advanced distribution facilities is the process of opening boxes for receiving and returns.

As trucks are offloaded, a typical bottleneck in the material flow is found with many people manually cutting boxes open. The results are quite expensive when looked at in terms of labor, turnover, injuries, and product damage.

An automatic case splitter is extremely useful for receiving applications.

1. A basic system will open 600 cases per hour, or advanced up to 1100 per hour
2. Systems lease for as little as $1000/month, which is less than 1/2 of a single employee burden
3. The cost of a single injury from a box knife can cost more than the machine that alleviates such injury

Given the constant need to streamline, amplify throughput, and improve safety, it is clear that an automatic case splitter can fill a void that exists in most operations, even the most automated facilities.

Most companies do not consider the extra costs of installing a conveyor system aside from the material and engineering they purchase from the seller or integrator. The fact is, traditional 480 volt conveyors require large electrical panels as well as onsite PLC programming.

In today’s world, 24 volt conveyors offer a lot of advantages. First off, most companies do not run more than 60 cartons per minute. In fact, the majority of distribution run at far less throughput. 15-30 per minute is much more typical. If you are one of the 90%+ in this situation, 24 volt systems are a great alternative.

Typical advantages of 24 volt conveyor systems include:

1. Built-in logic and controls (cartons will not touch each other, Zero Pressure Accumulation built in)
2. Installation only requires standard 110 volt plugin/drop
3. No onsite programming required
4. No PLC expenses
5. Uses less power than a 480 volt system

In summary, most distribution systems will benefit from advantages that traditional 480 volt systems simply do not deliver.

Let’s face it - we all want to spend as little as possible on just about everything.  The same goes for business. We are constantly tasked with spending less yet required to do more.

When it comes to automation, I find there are a lot of companies that are right in between justifying a  basic “something” and a more typical system that would really do the job nicely.

Packing and pick verification are two such examples which lend themselves to a variety of tasks that require people. An order is picked, a packer typically reviews the order and verifies contents, then will manually manifest the package with a scale, UPS computer, etc.

The use of either handheld or fixed position scanners along with packing software can provide both low cost and even provides proof of fulfillment.

The basic system works in this way:

• The picker drops off the order to QC area or order is conveyed to this area
• The packer then places empty carton on a scale (simple bench scale like used for UPS/FedEx)
• The operator scans the order number or manually keys it into system
• Each item that was picked is scanned and placed into carton
• Every time the scale is triggered with a product, the system:
  • verifies correct weight of the SKU
  • takes a still shot of the box from overhead to prove the item went into the box
• By the time the last item is scanned and weighed, the system prints a shipping label just like the typical pack stations use now.

Typical SolidPack station

It seems every time you turn around there is some new software package that does something…anything. I am impressed with the amazing ideas in the automation world. The fact that some guy can crunch a bunch of code together and make something perform a task at the right time, the right way, and even control it remotely from thousands of miles away when needed blows my mind.

The traditional methods of PLC conveyor controls are still still in play today. However, it seems that PC based controls are becoming more and more common.  A simple PC is able to easily house all the needed hardware to drive everything from simple diverts all the way to checkweighers, interfacing to WMS, ERP, and much more. Even more impressive is seeing an entire operation controlled by this single box sitting in the middle of the floow controlling sortation, driving picking decisions, and continuously logging, reporting, sending data to other systems, etc.

What is next? What will the next great invention bring? Software itself depends on hardware. PC’s are inexpensive and extremely flexible. Will it ever be replaced? Something to consider.

In these challenging economics it is important to realize there is a fixed cost associated to labor with many tasks including packing and shipping operations. Even if you normally ship out 5,000 cartons per day and now only ship 3,000 per day, the cost to do so is fairly static; or for argument sake maybe 1 less person.

The traditional business model includes perhaps a printed pick ticket, workers picking orders, then packing, scanning the order to produce a shipping label, weight, etc.

An automatic shipping system cuts out the touch labor associated with scanning, peeling/sticking shipping label, QC, etc. The process in a simple and low cost form is as follows:

1. The packed carton is placed on a conveyor with some sort of order ID (or license plate label)
2. The order ID is automatically scanned by a fixed position scanner
3. Carton weight is recorded by the inline scale (and dimensioned where required)
4. The order is looked up in the database, weight/dim recorded
5. Shipping label produced and automatically applied to the carton
6. Verification scan from fixed position scanner against shipping label on correct carton
7. Options for exceptions such as automatic reject for no-read, order not found, etc.

This type of system typically produces a 6 month to 1 year ROI depending on a few factors such as number of employees, number of cartons per day, etc.

We find that companies shipping at least 800 items per day have a very compelling business reason to automate this process. Click the links for more information on

• host interface
• automatic shipping
• labeling systems

CASI has opened this category to discuss all things picking and fulfillment related.

Topics could include

• Dispensing systems
• Zone picking
• Voice Picking

All comments will be submitted to moderator first. Feel free to drop your thoughts or solutions.

Automatic Case Extractor and Decaser

Prosper, TX, November 19, 2008, Cornerstone Automation Systems Inc. introduces ABOT ACE; a new application for automatic case extraction. ABOT ACE is a system designed to automatically index full cases or bags, cut tops, remove contents, and dispose of the box and/or lining. CASI is the only company offering a standard system that performs all of these tasks with applications such as mixing ingredients, depalletizing/repalletizing cases, as well as other food and custom solutions.

ABOT ACE can empty contents into hoppers, bins, super sacks, and conveyors. ACE separates liners and disposes of corrugate and plastic separately and automatically.

Boxes can be opened by cutting the tape seals, removing the top and cutting the liner. ABOT ACE will remove the top then open the liner inside allowing the contents to be poured from the case. ACE is flexible with programming to remove the liner with the contents then separating the liner from the contents.

ABOT ACE can pour many types of contents in a controlled flow at varying levels up to nine feet. Fill super sacks without need of conveyors or hoppers.

ABOT ACE is food grade rated and IP 67 for wash down capability. The ABOT cutter is available in IP 65 and stainless construction.

Automatic Case Extraction (ACE) Applications

• Nuts, trail mix, cereal, general ingredient mixing
• Cheese industry to decase blocks of cheese for processing
• IP 67 and food grade applications requiring full washdown NEMA 4X available

ABOT Decaser Features

• Many options for tooling available to fit individual needs
• System based on standard ABOT box cutter paired with standard robot for extraction
• Uses standard CASI PC based controls
• Auto depallatize and palletize where required

On the web: automatic case extractor