Distributed controllers, a digital network, and new human-machine interface helped an original equipment manufacturer more than double the throughput of a dock sortation system at Avon Products Inc. in Newark, DE.

Based in Phillipsburg, NJ, Tech Conveyor Inc. develops high-speed turnkey automated material handling systems. Engineers there increased Avon's throughput from 55 packages per minute to 120 with a newly designed Dock Sortation System. A distributed automation design minimized space requirements and simplified connectivity. The new design:

• Helped reduce size of control panels by 60%, distributing devices outside control cabinets;
• Reduced design and installation time for Tech Conveyor;
• Saved an estimated 40% on future Tech Conveyor designs; and
• Cut controls and wiring installation time by approximately 50%.

Avon, said to be the world's largest direct seller of beauty products, operates distribution centers throughout North America that house Tech Conveyor packaging, sorting and delivery operations. Avon's Newark distribution center, which sorts and ships an array of cosmetics, had used a 25-year-old shipping dock conveyor system. The conveyor system couldn't accommodate new packaging mixes, especially light-weight specifications.

"Avon was pushing the system to its limit," says Dave Van Winkle, manager, controls engineering, Tech Conveyor. The newly designed controls and conveyor system need to handle new packaging mixes, reduce labor costs, and keep production running smoothly faster than the 55 package per minute throughput. Tech Conveyor's installation included 160 Allen-Bradley ArmorStart distributed motor controllers and two Allen-Bradley SLC 5/05 programmable controllers from Rockwell Automation. The distributed motor controller minimizes space requirements and simplifies connectivity, allowing two or more motors to be connected to the same branch circuit. Installation and commissioning went more quickly with pre-engineered plug-and-play connections.

A DeviceNet network provides communication between controllers. The flexible and scalable nature of the digital network allowed Tech Conveyor to install additional pushbutton stations quickly, without conduit and wire-pulling. Allen-Bradley PanelView Plus operator interface terminals help locate issues with conveyor overload, and Allen-Bradley Bulletin 855 Control Tower stack lights and Bulletin 855H warning horns provide visual and audible indication of conveyor process changes. The new 5,100 ft system was installed in three phases, to accommodate Avon's seasonal production. Each phase involved Tech Conveyor technicians working on-site to ensure a seamless transition and startup.

Tech Conveyor plans to integrate similar technologies into other projects, including other Avon distribution facilities.

www.odva.org (for DeviceNet)

www.rockwellautomation.com

www.techconveyor.com