Is your conveyor system wasting energy and causing premature wear? A smarter approach can make all the difference. (Case Study: 6284)

Here’s how we helped a global leader in the HVAC manufacturing sector optimize their assembly lines.

The client's facility utilized motor-driven roller (MDR) conveyors for product accumulation. However, the system was programmed to run continuously, regardless of whether a product was present. This led to unnecessary energy consumption, increased mechanical wear and tear, and a less-than-optimal product flow.

The J+H Automation Solutions controls team implemented a strategic system upgrade. We re-engineered the logic on four separate assembly lines to create an intelligent, zero-pressure accumulation system. The project involved installing a total of 20 new, high-precision Keyence sensors to detect product presence accurately. This new sensory data feeds into the line's master Allen-Bradley PLC, which we reprogrammed to ensure conveyor sections activate only when a

product is ready to advance.

The result is a significantly more efficient and intelligent material handling system. The conveyors now remain stationary until needed, dramatically reducing energy costs and mechanical wear. This enhancement provides smoother, more reliable product handling and is a testament to how expert controls integration can unlock hidden efficiency in existing equipment.

We solve problems by building world-class automation. If you're ready to make your systems smarter and more efficient, let's talk about your next project.