Optimising warehouse efficiency with integrated conveyor, robotics and ASRS solutions

Warehouse automation is becoming increasingly important in New Zealand’s logistics environment. As customers expect rapid delivery as the norm, and manufacturers aim to stay competitive on a global stage, the ability to store, handle and dispatch goods quickly is essential. Advances in warehouse automation, like integrated conveyor systems, AGVs and ASRS warehouse solutions, are helping businesses achieve their goals more efficiently.

In recent years, the integration of conveyor technology with robotic systems and automated storage systems has become essential for businesses seeking to streamline operations. While robotics and ASRS warehouse solutions might get more attention, conveyors are central to these high-tech ecosystems. They connect different systems, provide continuous product flow, and reduce manual handling, making your operations safer and more consistent.

As a leading provider of conveyor solutions in New Zealand, MCL knows that production success hinges on effective coordination between all automation components. Understanding how these technologies integrate, and the conveyor integration challenges that can arise, can unlock new levels of flexibility and resilience in today’s demanding market.

Conveyors as the backbone of automation ecosystems

Conveyors might not have the sci-fi appeal of autonomous vehicles or sophisticated robotic arms, but these systems are the backbone of most automated facilities. They act as highways for goods in a warehouse, moving materials between the various stages of production or order fulfilment in a smooth, controlled manner.

Conveyors streamline material flow and facilitate robotic material handling, improving throughput. By providing a predictable path and speed for items, they enable robotic systems including AGVs and robots to pick and place products efficiently. When the flow of goods is predictable, robots don’t have to wait for new items to arrive, increasing productivity and creating a more consistent workflow.

Conveyor types

Several types of conveyors are commonly used in warehouse automation systems. Each type serves different purposes and can be adapted to specific industry requirements:

• Belt conveyors: Often used for moving lightweight or irregularly shaped items, belt conveyors feature a continuous loop that transports products smoothly. They work well in environments where stability and gentle handling are essential.
• Roller conveyors: These are typically used to move heavier items, like pallets or large boxes, across flat surfaces. Roller conveyors can be powered or gravity-fed, depending on the application. They’re well suited for general manufacturing, distribution centres, and bulk material handling.
• Spiral conveyors: Ideal for vertical transportation, spiral conveyors efficiently move products between multiple levels while conserving valuable floor space. They are particularly beneficial in warehouses and distribution centres with limited space.
• Cross sorter conveyors: Used for sorting and directing products to various destinations, cross sorter conveyors enhance automation accuracy and efficiency in logistics operations, distribution centres, and package sorting facilities.

Each of these conveyor types can work seamlessly within an automated ecosystem, with proper integration and careful planning to ensure the chosen conveyor suits the specific use case.

Supporting robotics and ASRS with conveyors

Conveyors optimise the performance of AGVs and ASRS warehouse solutions by serving as reliable links between them. Here’s how:

• Robotic picking and packing: Robotic picking solutions rely on the precise, continuous delivery of goods. Conveyors feed products into the robot’s workstation at a consistent rate, reducing idle time and labour costs.
• Robotic arms: These robots often perform repetitive tasks such as sorting, transferring, or palletising. When conveyors handle the infeed and outfeed, the robotic arms can maintain a steady workflow, improving overall efficiency.
• ASRS warehouse solutions: Automated storage and retrieval systems (ASRS) use advanced sensors and shuttles to move goods into designated storage locations or retrieve them for order fulfilment. By combining conveyor systems with ASRS, products can be transported to different points in the warehouse without interrupting the automated storage cycle. This reduces bottlenecks and travel times, leading to higher throughput.

For each of these scenarios, conveyors reduce manual handling and form a predictable, orderly process flow, which is crucial in any automation strategy.

Integration challenges and best practices

While the concept of blending integrated conveyor systems, AGVs, robotics and ASRS warehouse solutions is straightforward, the reality of merging different technologies can be challenging. Ensuring that all components communicate smoothly and maintain a consistent throughput can be difficult. However, several best practices can minimise these risks and set up a successful automated environment.

Common integration challenges

1. Compatibility of control systems
   Robotic material handling systems, ASRS solutions, and conveyors might use different control methods. If these controls don’t communicate well or align in timing, inefficiencies can arise like items colliding on the conveyor, inaccurate product tracking and robots idling.
2. Synchronising speeds and throughput
   Each piece of equipment runs at its own optimal speed. A conveyor might transport items at one rate, while a robotic picking arm might be designed for another. When there is a mismatch, bottlenecks can form, and certain parts of the system may end up waiting for the others to catch up.
3. Product positioning and orientation
   Many robotic material handling solutions rely on exact product orientation. If items arrive misaligned, a robot or an ASRS crane might struggle to pick them correctly, slowing down overall throughput. Proper sensor placement and quality conveyor design are essential to keep everything in position.

Best practices for successful integration

1. Early collaboration between automation providers
   Bringing suppliers and integrators together early in the planning process creates a shared understanding of each system’s requirements. Whether it’s power ratings, sensor selection, or desired throughput, addressing these details from the start helps prevent problems.  
2. Rigorous testing before implementation
   Piloting the proposed solution in a test environment allows teams to validate assumptions and troubleshoot any issues with controls and mechanical 

design. This step also confirms that any software or hardware modifications are made before full-scale implementation across the entire operation.

Conclusion

Embracing a holistic automation strategy that includes integrated conveyor systems, robotics, and ASRS warehouse solutions can redefine the efficiency and productivity of your business. Conveyors serve as the backbone of this automated ecosystem, ensuring that goods flow smoothly and allowing each piece of the puzzle to perform at its best.

By integrating these technologies thoughtfully and overcoming the conveyor integration challenges involved, warehouses can see noticeable improvements in throughput, accuracy, and safety. Predictable product movement, flexible design, and streamlined processes mean reduced operational expenses and a stronger competitive edge.

At MCL, we’re specialists in integrated conveyor solutions that work seamlessly with robotics and automated storage systems. Whether you’re exploring a first step into conveyors or seeking to unify entire systems, a conversation with MCL can clarify your options and outline a custom solution to meet your business’s unique needs.

Ready to learn more? Contact our team today to take the first step towards optimising your material handling processes.