Case Studies

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Automated Distribution Warehouse Labelling System

ALTech have recently installed multiple ALritma and ALcode labelling heads into Smyths Toys’ new 500,000 sq.ft. Corby automated distribution warehouse with high bay storage and automated picking facilities. Smyths Toys, being one of the leading provider of children’s toys and entertainment products, require 24/7 operation and as such reliable and robust labelling machinery is critical to their business.

There are two key applications on this site; order start ‘licence plate’ sequential barcode labelling and end of line carton shipping labelling.

‘Licence plate’ sequential barcode labelling gives the box an identity and is applied to the front and back of newly formed empty cartons as they exit a Comarme case erector, whilst still being securely held within the side drive units of this system; the labelled boxes are then inducted onto the automatic conveying system.

Pre-printed sequential labels are applied via a pair of horizontally opposed opposite handed ALritma labelling heads with standard peeler applicators. Following application, confirmation of matching codes on each side of the carton are verified using a pair of barcode readers. This read also ‘announces’ the box’s existence to the Warehouse Management System (WMS) and an order is allocated to the box; the automatic conveyor then routes the box to the required pick locations in the warehouse.

For simplicity of WMS integration Smyths Toys chose to make use of digital label production and apply a pre-printed sequential label stock; ALTech are also able to and more frequently supply on demand print and apply solutions to perform the task in real time.

Once the boxes have travelled around the extensive warehouse conveyor system, and the order has been allocated and picked to the box, they return to one of six despatch lines equipped with various fill packaging, strapping and carton closing technologies (depending on the type of product being shipped). Each line is fitted with an extremely robust ALcode one-to-one print and apply labelling system with a long stroke ‘tamp’ applicator that is able to accommodate boxes of varying heights via its digital pressure sensor system and Festo pneumatics.

The routing barcode on the box is read and the conveyor control WMS sends label data directly to the Zebra ZE500 printer to print the customer/order specific courier and shipping address information. Low level conveyor control handshaking it conducted via volt free i/o contacts, configurable to the requirements of the application.

ALTech have worked with a number of automated warehouse system integrators for many years and their solutions have long formed the backbones on many business critical operations providing testament to the low running costs and reliability of ALTech labelling machinery. Smyths Toys also highlights the breadth of ALTech’s range, offering both print and apply and standard decorative labels applicators, whereas most competitors are only focused on one specific area.

ALritma routing label applicators:

ALcode shipping label print & apply labellers:

Proven modular print and apply label application solutions for any barcode identification/traceability requirement.

Contact ALTech UK to discuss your requirements with our experienced and knowledgeable team.

More than 30 years established as a leading manufacturer of labelling machinery with a world wide install base.

Contact ALTech UK to discuss your requirements with our experienced and knowledgeable team.

We tailor design every labelling system to the exact requirements of our customers, ensuring they fully meet their needs.

Contact ALTech UK to discuss your requirements with our experienced and knowledgeable team.