An insight into the Tokyo distribution centre of Nippon Record Center - focusing on the Interroll Crossbelt Sorters

The multimedia industry is attracting more and more customers at whirlwind speed; while the intervals between new, much sought after products are becoming shorter and shorter. The result: The number of mass consumer goods, such as DVDs and CDs, is increasing constantly. Therefore, faster, precise and, above all, economical distribution has become a key competitive factor. The "Chuo" distribution centre of Nippon Record Center (NRC) is a striking example of an efficient and effective in-house distribution process. Experts will be able to take a look at the entire system and the cost-effective, impressive Interroll solutions on 14 February 2008; with special focus on the Interroll Crossbelt Sorters.

Redundancy principle: all in good time
A consistent reduction of risks ensures comprehensive productivity. The sortation technology at the "Chuo Center" in Atsugi, near Tokyo, is based on high availability due to redundancy and greater reliability thanks to a proven mechanical concept. Two linear Interroll Crossbelt Sorters convey and distribute up to 3,000 multimedia units an hour. Each crossbelt sorter has a total of 41 destinations positioned along both sides, equipped with chutes and rollers to ensure smooth unit load handling.

Cost-effective handling of a wide range of goods
NRC demonstrates that the Interroll Crossbelt Sorters are well suited to the various products of this JVC subsidiary. Depending on the actual size of the order and the type of recipient, the DVDs, CDs, sheet music, music magazines and catalogues are placed on the Interroll Crossbelt Sorters in either cardboard boxes or envelopes. This means the crossbelt sorters at NRC have to handle goods of various shapes, sizes and weights. The surface structures and the position of the centre of gravity also vary considerably. All these products are transported and distributed safely and economically by the Interroll Crossbelt Sorters; even at throughputs as low as 2,000 items an hour. There are so many good reasons for NRC to use Interroll sortation technology. For example, it took the system integrator Okamura just six weeks to install the crossbelt sorters at the Chuo Center - one of three NRC distribution centres in Japan for the domestic market.

Gentle sorting
Interroll Crossbelt Sorters can handle weights ranging from 50g to 35kg and are capable of transporting and distributing almost any item which has to reach the right recipient at the right time. Even at peak times, the crossbelt sorters meet all the complex demands with throughputs of up to 13,000 items per hour: From the precise transfer of items from synchronisation belts to crossbelt carriers and safe transport to gentle discharging at the correct destination. And zero error tolerance guarantees realisation of the mechanical principles.

Mechanical reliability
Reliability based on mechanical robustness and high quality components begins for Interroll Crossbelt Sorters with the positive drive: Spur gear motors which are far more energy efficient than their linear counterparts. Each crossbelt carrier is connected to the next by a steel wire-reinforced rubber block chain with linked attachments. The main feature of an Interroll Crossbelt Sorter is the crossbelt carriers with patented mechanical drive. Once a crossbelt carrier reaches its allocated destination, a pressure plate is pneumatically positioned within the sorter to ensure that the drive wheel underneath the crossbelt carrier scrolls against it. The movement of the carrier is converted for the drive of the crossbelt. The cardboard boxes and envelopes slide down the respective destination chutes without the need for an additional power supply. Therefore, the Interroll Crossbelt Sorters combine exceptional reliability with low operating costs and minimum maintenance thanks to less wear and tear. Positive side effect: Low noise operation due to the application of high quality materials and components, such as the polyurethane coated wheels of the crossbelt carriers in aluminium profiles (linear sorter). This results in a pleasant, quiet working environment for the 600 employees at the Chuo Center.

Quick and easy installation due to pre-assembled sorter modules
The system integrator Okamura benefited greatly from the numerous Interroll Crossbelt Sorter innovations: Due to their plug & play design the pre-assembled sorter modules can be installed and integrated into the overall system quickly and easily on site. But a particular advantage for distribution centres like NRC is the compact modular design of the Interroll Crossbelt Sorters, which saves lots of space. This space saving design also increases the flexible planning options of system integrators. Depending on the provided space and application requirements, either a vertical sorter (linear structure) or a horizontal sorter (circular structure) can be employed. Besides the two vertical sorters, Okamura also installed space saving Interroll belt conveyors at NRC.

International customers
Since 1999 Interroll has installed 65 vertical and horizontal crossbelt sorters at more than 40 locations around the globe, including Japan, Singapore and the Philippines. Today, Interroll Crossbelt Sorters are used to sort and distribute goods at distribution centres, mail order companies, courier, express mail and parcel service providers, postal services as well as other logistics service providers. Classic unit load handling includes letters, small parcels, packages, bundled newspapers, bundled letters, leaflets, poly-bags, video cassettes, multimedia products, clothes and packed foodstuffs.

Long-term investment
Interroll Crossbelt Sorters are designed to provide users with crucial logistical and financial certainty via the highly available, easy-to-handle sortation technology. These sorters offer the perfect solution for future growth as a long term economic investment with a quick ROI of two to three years.

The Interroll group
The group provides international cutting-edge technology spanning the entire value chain for a diverse range of industries. Interroll has established a leading worldwide position in selected products and solutions for internal unit load handling. Founded in 1959 and listed on the Swiss Stock Exchange SWX, the company currently employs around 1,300 people at 27 companies. Interroll is divided into three globally active business units under the leadership of a strategic holding company based in Sant'Antonino, Switzerland. The conveying components from "Interroll Drives & Rollers" principally support regionally oriented plant manufacturers and OEMs. "Interroll Dynamic Storage" and "Interroll Automation" predominantly supply modules and sub-systems to globally operating system integrators, multi-national companies and end customers. Unit load handling from Interroll focuses not only on mail and parcel distribution but also on the foods and drinks industry, airport technology, logistics service providers, industry and applications in the healthcare sector.

Courtesy of  Interroll