The system layout consists of 5 racks with a total of 10 modules in each. Each module contains 12 belts with 25 tiers of bottles. Each room is connected to the rest of the facility by 2 conveyor systems that service the product flow into and out of the racks. The conveyor extension and drive system is integrated into the existing 2-level main track conveyor with incoming product on the bottom level and outgoing product on the upper level.
The team made the largest system impact on the front end. Incoming bottles are diverted from the main track conveyor and travel to the ramp conveyor, where the bottle translator is located. The bottle translator moves the bottles into the “up-ender” where they are individually rotated from a vertical to a near-horizontal position. The bottle translator replaces their existing system, which had a high failure rate.