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Automated Material Flow System for E-comm Center

A fully automated and remotely monitored material flow system is part of a modern, 6,000-square-meter distribution center of Cookplus in Hadimköy near Istanbul, Turkey.

The advanced Interroll conveyor system at Cookplus is entirely managed by software developed by Teknokom.
The advanced Interroll conveyor system at Cookplus is entirely managed by software developed by Teknokom.

Interroll teamed up with systems integrator Teknokom on the design and installation of the sophisticated system. Essential elements of the new material handling solution are the RollerDrive EC 5000, MultiControl, and the Modular Conveyor Platform (MCP) from Interroll. The system combines advanced features such as travel control, automatic invoice printing, dynamic volume measurement, cargo label applications, and real-time monitoring.

Cookplus is the e-commerce brand of Karaca Group, a leader in the tableware, kitchen, and home textile market, operating with 2,700 dealers and shops in 27 countries. The zero-pressure-accumulation conveyors used for this material flow solution have a length of more than 220 meters interconnecting a variety of picking stations with the packaging and shipping areas on two floors of the facility. The efficient and extremely energy-saving conveying of totes and parcels uses about 190 RollerDrive EC 5000 units being controlled by 60 Interroll MultiControls cards connected to a programmable logic controller (PLC) and a warehouse management system.

“With our new solution we dramatically increased the performance and capacity of our distribution and fulfilment center by avoiding a variety of complex manual internal processes. Just as important to us as increasing our efficiency was further improving customer satisfaction through very fast and reliable deliveries,” says Ertugrul Celebi, Chief Operating Officer, Logistics & Supply Chain, at Karaca A.S.Automated labeling is part of the new material flow system at Cookplus.Automated labeling is part of the new material flow system at Cookplus.

The advanced conveyor system is entirely managed by software developed by Teknokom, a long-standing member of the Rolling On Interroll program, Interroll’s international partner network. The software applications use the data gathered by Interroll’s MultiControl cards for controlling and monitoring purposes. One example is an intelligent travel control feature that allows bypassing picking stations or a complete floor if no action from operators is needed. Moreover, at the end of the picking operation, before packaging, a printer automatically equips every order with the respective invoice. Upon entering the shipping area, a label applicator automatically pastes to each order a barcode label for the forwarding agent; this label contains all of the necessary information, including the order destination, volume information, and a list of contents.

Go here to read about how one New Jersey-based 3PL is tackling e-comm order fulfillment.

Teknokom’s software application allows for monitoring the whole material flow process for maintenance and support purposes via a user-friendly interface, which offers controlling as well as reporting features. For example, the locations of the totes, the actual status of the orders, and the picked items in a single tote can be seen for both floors. Moreover, operation managers can receive live as well as time-frame-based reports about order fulfillment capacity, bottlenecks in the picking stations, error reports, and detailed performance information.





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