CASE STUDY: Returns Processing Solution using ABOT Magnum Automatic Box Opener

The Problem: Automated Returns System to lower labor Costs

A major supplier of satellite receivers wanted to automate their returns processing facility to lower labor costs. Studies have shown that a returns processing operator can open about 100 cases per hour. Manual designs for the new facility showed 20 operators cutting boxes to obtain the 1800 carton per day rate.

The Solution: ABOT Magnum Automatic Box Opener

CASI proposed a solution using the ABOT Magnum Automatic case opener system along with transport and trash conveyor.

Cartons are loaded onto a powered extendable conveyor that allows the loaders to load cartons onto the conveyor from the trucks. Two extendable conveyors are used normally at the same time.

Cartons are transferred and merged from the two extendable conveyors by a pair of SortMaster 100 bi directional sorters. This puts the cases from both dock doors on a single transport conveyor into the automatic box openers.

Return cartons are fed into all four in feeds of the ABOT magnum system using the SortMaster 100 system.

Cartons stage in the ABOT System and are processed using the patent pending ABOT design. ABOT handles even the most difficult damaged cartons and is a perfect choice for returns.

Once the cartons are cut, the product is transferred out to zero pressure accumulation conveyor. This conveyor transports the cartons to processing stations where the receiver is removed and processed. Trash such as cartons are transported to a compactor using trash conveyor as shown.

The ABOT’s advanced controls can provide unlimited recipes for cutting. Optional barcode scanners can be used to automate the entire returns process as well as adjust cut recipes on the fly. The system is very powerful and can control the entire conveyor system through use of an as-I network and the optional SolidRoute Conveyor Controls Module.

Benefits from the new efficiencies

Benefits from the system include reduced labor from the automated process and the confidence to know that the automatic system is ensuring the right label is on the receiver. The unit in sorted after the labeling process to the correct palletizing zone.