In small and medium-sized logistics centers, incoming bulk flows of truck loads are usually separated manually. This time-consuming process can often be observed in the logistics of CEP services or online retailers, for example in micro-depots for the last mile. Unloading swap bodies or lattice trolleys at the start of the conveyor line often involves 20 employees. Packages are handled individually and have to be sorted and placed one after the other on bulky inbound conveyors. Due to the increasing shortage of skilled workers and the growing shortage of space, this process is not sustainable. Automated conveyor systems relieve employees and minimize the space required for logistics.

To date, however, there has been a lack of cost-effective automation solutions that are suitable for small and medium-sized logistics facilities. Standard systems on the market are expensive, require a lot of maintenance and take up too much space. Conventional systems generally fulfill one of two exclusion criteria: With a throughput of over 15,000 parcels per hour, some are only suitable for high-performance distribution centers of large corporations; smaller systems unnecessarily consume valuable space that would otherwise be available for other logistics processes by recirculating the parcels. Recirculating means moving the parcels in a circle until the correct separation is achieved. This uncontrolled random singulation requires additional, space-consuming conveyor lines. In addition, the implementation of an automation project often takes several years.

Singulate 6,000 packages on five square meters

Cellumation, a specialist in automated conveyor technology, has tackled precisely this problem. At this year's LogiMAT, the Bremen-based scale-up presented its CV-Singulate, which automatically brings chaotic parcel volumes into an orderly flow. The singulating system is based on the modular Celluveyor technology consisting of robot cells. Cellumation offers the CV-Singulate in five variants so that it fits into any conveyor concept. The throughput of the singulation solution is between 2,000 and 6,000 parcels per hour, depending on the variant. In the smallest version, the system only takes up 1.2 square meters of space. Even the largest version, at five square meters, is almost two thirds more space-saving than conventional systems in this performance class. The delivery time is currently 24 weeks; the plug-and-play solution can be integrated within a weekend. Maintenance takes even less time: if necessary, the robot cells can be replaced within five minutes.

As a start-of-line solution at goods inwards, the CV-Singulate converts an incoming bulk flow into a continuous outgoing flow. The singulating solution arranges a chaotic flow of packages (bulk) so that the individual objects follow one another at individually defined minimum distances. The Celluveyor technology in combination with an intelligent vision system ensures the ideal alignment and orientation of these objects. As the system places the parcels in the optimum sequence straight away, there is no need for the usual extra rounds of recirculation. In addition, unlike conventional solutions, the system has up to two outlets instead of one, which means that a bulk can be separated on up to two conveyor lines simultaneously. This opens up new possibilities for distribution centers: they can either double their productivity in the relevant area or singulate twice as many parcels in the same space.

Real-time planning for ideal order

Designed digitally from the outset, the system's control technology enables packages to be controlled in a targeted manner. The vision system's 3D cameras scan what is happening on the Celluveyor in real time and recognize the contours of the objects to be conveyed with millimetre precision. The system recognizes and moves the individual objects in the optimum orientation. As the packets always leave the system in the same orientation (either long-side or short-side loading), they can always be processed with the same quality. This prevents packages from getting stuck, which would require manual intervention or even result in downtime. In addition, some upstream and downstream work steps, such as manual alignment of the objects, are eliminated.

The bottom line is this: Automated conveyor technology is becoming indispensable in many areas of logistics: it reduces the amount of space required and frees up employees to focus on other, more value-adding activities. However, there is often a lack of systems that are suitable for small and medium-sized logistics centers. This is particularly evident in singulating, where all viable solutions are geared towards high-performance distribution centers of large corporations. The CV-Singulate from Cellumation is an alternative here. Even the smallest version of the automated singulation system requires 1.2 square meters of space and achieves a throughput of 2,000 parcels per hour. The system thus offers logistics companies a glimpse of the automated singulating of the future.