Conveyor Handling Company and Hytrol partnered with Dotcom Distribution to automate outbound carton handling at its Edison, New Jersey facility, supporting a fulfillment operation built around each customer’s brand.
Dotcom’s customers needed distinctive packaging alongside dependable order processing. The challenge was to automate shipping tasks while preserving that customized presentation.
Serving both retail outlets and individual consumers meant balancing retailer routing requirements with a branded unpacking experience. The system also had to accommodate a varied product mix.
Existing proprietary software limited throughput and future development. Dotcom needed more flexibility, with an implementation plan that kept disruption to daily fulfillment low.
Automatic weight and dimension capture, together with shipping-label application, reduced manual touches. Package measurements also supported real-time shipping decisions. Takeaway conveyor cleared finished cartons from packing workspaces. Implementation planning helped limit disruption while the new system was introduced.
Hytrol E24 and EZLogic provided controlled accumulation and spacing before scanning. CHC connected conveyor operation with the warehouse management system, shipping sorter, and PLC-based controls.
An open software solution replaced the restrictions of the previous platform, giving Dotcom greater flexibility to expand the system.
Batch-picked orders arrive at packing benches, where associates prepare shipping cartons.
Takeaway conveyor transfers cartons toward the Gapper-L and scanning area.
Overhead scanning reads carton IDs; in-motion measurement captures shipment data for the warehouse management system.
The shipping sorter routes cartons to their assigned destinations.
| Equipment / System | Role |
|---|---|
| Hytrol E24 & EZLogic | Accumulation and carton spacing ahead of scanning. |
| Gapper-L & overhead scanning | Carton separation and identification. |
| WMS & PLC-based controls | Information exchange with conveyor and sortation. |
| Open software solution | Flexibility for future system expansion. |
The project connected personalized packing with automated shipping preparation. Dotcom retained its emphasis on brand presentation while reducing repetitive handling and creating room for future growth. CHC's innovative engineering resulted in expanded capacity, improved speed and accuracy, and a significant reduction in manual labor.
Automated shipment preparation reduced the handling required after packing. Captured package data supported cost-conscious routing, while the takeaway conveyor freed bench space for subsequent orders. The open software architecture also provided a foundation for future development.
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