In distribution centers and warehouses, where space optimization and streamlined processes are essential for peak efficiency and productivity, traditional methods of empty carton and tote movement can sometimes struggle to meet the dynamic needs of the environment. Overhead conveyor systems, often referred to as monorails, provide an effective solution to these challenges. They elevate the process quite literally, using the often under-utilized overhead space. Below is a list of seven advantages overhead monorails bring to distribution center and warehouse operations.   

1. Occupies Unused Overhead Space and Frees Up Floor Space 

One of the most significant advantages of integrating an overhead monorail system is its ability to utilize the often-overlooked overhead space. Unlike other carton delivery and removal methods that consume valuable floor space, overhead monorails free up the ground for more critical operations. This not only improves the flow of movement within the facility but also enhances safety by reducing clutter and potential tripping hazards.  

2. Centralized Storage of Corrugate and Loading of Empty Cartons 

Efficiency in distribution centers is heavily dependent on the streamlined handling of materials. Overhead conveyors facilitate the centralized storage of corrugate, simplifying the process of loading empty cartons. This centralization minimizes the time and labor required to manage these materials, leading to more efficient operations.  

3. Allows for Empty Carton Delivery at an Ergonomic Height 

Ergonomics plays a pivotal role in maintaining a productive and healthy workforce. Overhead conveyors are designed to deliver cartons at an ergonomic height, minimizing the need for excessive bending or stretching. This enhances worker comfort and significantly reduces the risk of injury, contributing to a more satisfied and efficient workforce. 

4. Custom Designed Carriers to Maximize Delivery Rates 

Every distribution center has unique needs based on the size and type of cartons handled. Pacline offers custom-designed carriers tailored to maximize delivery rates for specific carton sizes. 

5. Modular Components for Ease of Expansion and Modification 

The needs of a distribution center can rapidly change, necessitating flexible and adaptable solutions. The PAC-LINE™ enclosed track monorail is modular, allowing easy installation, expansion and modification. This modularity ensures that the system can grow and adapt with the business, providing a long-term solution. 

6. Compact and Low-Profile Design to Allow for Versatile Routing 

Space optimization in distribution centers isn’t just about using vertical space; it’s also about intelligently navigating around existing structures and equipment. The compact, low-profile design of PAC-LINE™ overhead conveyors enables versatile routing options, ensuring that the system can be integrated into a variety of spaces without requiring significant alterations. 

 7. Easy to Maintain 

Maintenance is a crucial consideration for any equipment in a distribution center. Overhead conveyors are engineered for ease of maintenance, with simple procedures for chain tensioning and lubrication. This ease of maintenance ensures minimal downtime and consistent operational efficiency. 

An overhead conveyor system is a cost-effective investment in operational efficiency, safety, and scalability to optimize empty carton handling processes. Contact us today to speak with one of our Engineers!