1. Unloader

Brings hand-loaded packages, introduced to the unloader by a package handler, into the sortation process.

ISSUES

Belt tracking issues are damaging the belt due to unsquared belt splices, belt over tensioning, or incorrectly installed hooks.

SOLUTIONS

SmartClamp™ Belt Clamps work particularly well when stringing new belting onto an extendable loader. The SmartClamp engages quickly with the belt, while the pull loop provides a handle for hand pulling the belt onto the extendable unloader.

Belt splices that are not installed into a square cut belt end are a primary cause of belt tracking issues with unloaders. The Laser Belt Square is the quickest and most accurate way to locate your perfectly-square belt cutting reference line.

The 845LD Belt Cutter is widely accepted as the wide belt cutter of choice. It allows for the safe cutting of the belt in a single pass and a quick engaging belt clamp system, easily toggling over to apply the perfect amount of spring-loaded pressure to the belt, preventing belt migration during the cut. This ensures a straight cut every time.

Quick to install with great performance, Clipper^® and Anker^® Wire Hooks are the belt joining method of choice. The most common sizes of wire hooks used with unloader conveyors are #1 and #2SP carded style, in High Tensile (HT) wire. Unibar UX1 (A40) and U2SP (A2SPS) in 430SS are also used. The HT carded is the best choice for added impact resistance and extended wear life.

The Nylosteel Durastainless™ (DSS) Hinge Pin is perfect for use with unloader conveyors. In extendable unloaders there are a minimum of 10 pulleys that the belt makes a transition around. The increased hinging action requires a better-wearing pin like the DSS.

Roller Lacer® and Roller Lacer® Gold Class™ installation tools are perfect for quickly installing wire hooks in one single, easy operation, ensuring that the splices are installed correctly.  

1 a.) SMALL SORT PROCESS – Secondary Sort

A sortation dedicated to small packages. The small sort is fed both from the primary sort, through the use of shipping bags, and from the inbound tractor trailers. Packages coming from the tractor trailers are placed on a Small Sort Transport Belt that only feeds the small sort. The shipping bags that are filled with packages are arriving from other hubs can also be placed on this belt, but are often placed into the general primary sort where they are diverted to the small sort area of the plant along the way. Smaller sortation hubs also use a manual process to sort the small packages and parcels.

ISSUES

• Small packages or envelopes are becoming lodged in the transfers.
• Belt splice failures are occurring due to worn hooks and hinge pins.
• Improperly squared belts are causing belt tracking issues that could damage the belts.

SOLUTIONS

Flexco Segmented Transfer Plates are designed to be placed with little to no clearance between the segments and the belt. This helps to greatly reduce the chances of envelopes, plastic shipping bags, and other small parcels getting sucked into the transfer and damaged.

Clipper® and Anker® High Tensile Wire Hooks are easy to install and a great option to increase splice life, providing superior abrasion resistance.

Durastainless™ (DSS) Hinge Pins provide up to 10 times the wear life. This keeps the small sortation lines up and running during critical sortation times.

The Laser Belt Square will make finding an accurately-located square cutting reference line much easier. Using the Laser Belt Square will significantly reduce belt tracking issues related to crooked splices caused by unsquared belt ends.

1. TILT TRAY SORTER – Secondary Sort

Part of the secondary sort, this conveyor runs in a continual oval pattern with a tray on top of each “car.” When the tray reaches the proper location it will tilt or tip, allowing the small package to slide off.

2. CROSS BELT SORTERS - Secondary

Part of the secondary sort, these articulating belt conveyors divert packages off to their destination chute.

ISSUES

The endless splices are failing, resulting in belt damage.

SOLUTIONS

The Novitool® Aero® Splice Press and the Novitool® Pun M™ Mobile Finger Punch provide the fastest and most accurate endless splicing available. And the flexibility of power options through the simple change of a cord allow the Aero Splice Press to be used virtually anywhere in the sortation facility.

2. Unloader Incline

Introduces the packages and parcels into the general sortation flow, feeding laterally onto either a recirculation conveyor or a primary feed/transport conveyor.

ISSUES

• The belt is being damaged due to unsquared belt splices and incorrectly installed hooks.
• Foreign object debris/fall-out debris (FOD) is lodging in the transfer due to the warping of transfer plates, causing damage to the belt and/or packages. 

SOLUTIONS

Belt splices that are not installed into a square cut belt end are a primary cause of belt tracking issues with unloaders. The Laser Belt Square is the quickest and most accurate way to locate your perfectly-square belt cutting reference line.

The 845LD Belt Cutter is widely accepted as the wide belt cutter of choice. It allows for the safe cutting of the belt in a single pass and a quick engaging belt clamp system, easily toggling over to apply the perfect amount of spring-loaded pressure to the belt, preventing belt migration during the cut. This ensures a straight cut every time.

Quick to install with great performance, Clipper^® and Anker^® Wire Hooks are the belt joining method of choice. The most common sizes of wire hooks used with unloader incline conveyors are #1 and #2SP carded style, in High Tensile (HT) wire. Unibar UX1 (A40) and U2SP (A2SPS) in 430SS are also used. The HT carded is the best choice for added impact resistance and extended wear life.

The Nylosteel Durastainless™ (DSS) Hinge Pin is perfect for use with unloader conveyors. In extendable unloaders there are a minimum of 10 pulleys that the belt makes a transition around. The increased hinging action requires a better-wearing pin like the DSS.

Roller Lacer® and Roller Lacer® Gold Class™ installation tools are perfect for quickly installing wire hooks in one single, easy operation, ensuring that the splices are installed correctly.

The segmented design of the Flexco Segmented Transfer Plate allows individual segments to release in the event that foreign object debris/fall-out debris (FOD) lodges into the transfer plate. This virtually eliminates the potential for warping by either the segment lifting up, allowing the FOD to fall harmlessly through, or by ejecting from the bar in a more extreme event, taking the FOD with it.

3. Recirculation or Primary Feed Transport

Starts the packages and parcels on their journey toward the actual sortation process.

ISSUES

• Foreign object debris/fall-out debris is becoming lodged in traditional transfer plates, damaging conveyed packages.
• Foreign object debris/fall-out debris is becoming lodged in the hitch/protector guard, damaging conveyed packages.
• The belt is being damaged due to unsquared belt splices and incorrectly installed hooks.

SOLUTIONS

Segmented Transfer Plates significantly reduce the chances these longer belts will become damaged due to foreign object debris/fall-out debris (FOD) being caught at the transfer area. And the potential for damage to conveyed packages in the transfer area is virtually eliminated.

The Flexco Hitch Guard is designed to create a tight seal in the hitch area, protecting the hitch from shipping bags, plastic shipping bags, and general FOD getting pulled into the hitch. And the patented segmented design allows a single segment to raise up or release in the event a piece of debris does become lodged between the hitch guard and the pulley.

Quick to install with great performance, Clipper^® and Anker^® Wire Hooks are the belt joining method of choice. The most common sizes of wire hooks used with recirculating/transport belts is #3, in High Tensile (HT) wire.

The Roller Lacer® Gold Class™ is perfect for wider belts, installing the hooks in one easy operation up to 50% faster than manual operation.

4. Singulator

Reorganizes bulk flow packages into a single path of packages, all oriented to the same side of the conveyor.

ISSUES

Belt splices are failing due to fastener and hinge pin wear and improperly squared belts.

SOLUTIONS

Singulators incorporate live roller drive belts that see contact with the upper rollers continuously, so Clipper® and Anker® High Tensile Wire Hooks are a great option to increase splice life.

The additional wear life provided by the hybrid coating on the Durastainless™ Hinge Pins will extend the life of the pin and of the wire hook splice in these high-speed, short belt length systems that expose the splice to many more pulley transitions per day, thus more hinging action.

For 72” (1800mm) wide Singulator recirculation belts, a 72” (1800mm) wide Roller Lacer is recommended. This will speed up the hook installation process with a quality finished splice.

Having a 72” (1800mm) 845LD Belt Cutter on hand will make cutting the wider 72” (1800mm) belts safer, more accurate, and quicker than using a straightedge and utility knife.

The Laser Belt Square will make finding an accurately-located square cutting reference line much easier with the 72” (1800mm) wide Singulator recirculation belts.

5. Gapper/Metering Conveyor

Places an equal gap between the packages in the singulated flow.

ISSUES

• Belt splices are failing due to hinge pin wear and improperly squared belts.
• Foreign object debris/fall-out debris is becoming lodged in the transfer.

SOLUTIONS

For conveyors like these, with short lengths and high belt speeds, Durastainless™ (DSS) or Duralink™ (DL) Hinge Pins are an optimal solution for long wear life.

Segmented Transfer Plates for transfers from 1.5"(38mm) to 3" (75mm) can significantly reduce the chances of foreign object debris/fall-out debris catching in the transfer areas and damaging the belt.

The Laser Belt Square will make finding an accurately-located square cutting reference line much easier.

6. Scan Tunnel

Reads shipping labels, takes dimensional measurements of packages, and sends this information on to the sorter.

ISSUES

• Belt splices are failing due to worn hooks and hinge pins.
• Endless splices are failing and the belt is being damaged due to an unsquared belt.

SOLUTIONS

Clipper® and Anker® High Tensile Wire Hooks are easy to install and a great option to increase splice life, providing superior abrasion resistance.

Since scan tunnel conveyors are shorter in length and run at higher speeds, the better-wearing hybrid coating of the DuraStainless™ Hinge Pins perform well in high pulley cycle application.

The Laser Belt Square will make finding an accurately-located square cutting reference line much easier.

Scan tunnel belts are extremely important to the sortation operation. The clean, square cut generated by the 845LD Belt Cutter ensures that these important belts track straight.

When a scan tunnel belt breaks during a sort, repairs must be made quickly. The Roller Lacer® Gold Class™ can speed up the wire hook installation process by up to 50%.

For endless belts, the Novitool® Aero® Splice Press and the Novitool® Pun M™ Mobile Finger Punch provide the fastest and most accurate endless splicing available.

7. Sorter Induction Conveyor

Introduces the gapped/ metered and scanned packages into the sorter at the same speed as the sorter to ensure proper package positioning in the sorter.

ISSUES

Belt splices are failing due to worn hooks and hinge pins, causing belt damage.  

SOLUTIONS

Clipper® and Anker® High Tensile Wire Hooks are easy to install and a great option to increase splice life, providing superior abrasion resistance.

Sorter induction conveyors are shorter in length and run at higher speeds, so the better-wearing hybrid coating of the DuraStainless™ Hinge Pins perform well in high pulley cycle application.

The Laser Belt Square will make finding an accurately-located square cutting reference line much easier.

Sorter induction conveyor belts are extremely important to the sortation operation. The clean, square cut generated by the 845LD Belt Cutter ensures that these important belts track straight.

8. Sliding Shoe Sorter

Takes input information from the scan tunnel, converts the information, and then directs the package down the correct chute according to postal code.

9. Paddle Diverter & Push Sorter

Diverts the direction a package is traveling in towards a designated conveyor or chute.

ISSUES

• Splice damage from diverters is leading to belt failure.
• The belt is being damaged due to unsquared belt splices.

SOLUTIONS

Clipper® and Anker® High Tensile Wire Hooks offer exceptional wear, while providing a low-profile mechanical splice, which is important in paddle and push diverter applications. The low profile keeps the mechanical fasteners well below the bottom surface of the diverter.

The Roller Lacer® Gold Class™ is the perfect tool for properly installing Clipper® and Anker® wire hooks into diverter conveyor belts. The robust design of the Roller Lacer Gold Class head gives the lacer the strength required to fully compress wire hooks into belting material, creating the lowest profile mechanical splice possible

Durastainless™ (DSS) Hinge Pins provide up to 10 times the wear life. This keeps crucial diverter transport belts up and running during critical sortation times.

10. Gravity Roller Bed

Connects the sorter chute to the coal chute where packages are loaded onto tractor trailers. Also used to introduce packages to the metro lines and van lines.

10a. Metro Lines and Van Lines

Part of the outbound/secondary sort, these conveyors bring sorted packages to the package cars for local delivery.

ISSUES

• Poorly fitting transfer plates are increasing the potential for injury.
• Belt tracking issues, resulting in belt damage, is occurring due to improperly squared belts.

SOLUTIONS

Metro/Van lines are an area where there is direct human interaction with the conveyor system. When properly installed and maintained Flexco Segmented Transfer Plates provide a tighter seal to the belt which helps foster a safer work environment.

Clipper® and Anker® High Tensile Wire Hooks are easy to install and a great option to increase splice life, providing superior abrasion resistance.

The Roller Lacer® Gold Class™ is the perfect tool for properly installing Clipper® and Anker® wire hooks into metro/van line conveyors.

Durastainless™ (DSS) Hinge Pins provide up to 10 times the wear life. This keeps the metro/van lines up and running during critical sortation times.

The Laser Belt Square will make finding an accurately-located square cutting reference line much easier. Using the Laser Belt Square in these applications will significantly reduce belt tracking issues related to crooked splices caused by unsquared belt ends.

The conveyor belts used on metro/van lines tend to be 48” to 60” (1200 to 1500mm) in width. The 845LD Belt Cutter makes quick work of cutting these tough, heavy belts in a single pass.

11. COAL CHUTE

Packages collect in the coal chute as the package handler offloads them into a tractor trailer.

12. EXTENDABLE GRAVITY ROLLER BED

Loads packages into the back of a tractor trailer. Usually located directly below the coal chute.

13. IRREGULAR (IR), INCOMPATIBLE (IC), NON-CONVEYABLE (NC) LINE

Carries the large, heavy, or oddly-shaped products. The IR/IC/NC line quite often runs perpendicular to the unloader conveyors and under the unload incline conveyors. This line generally runs the length of the building/the full length of the unload doors in the building.

ISSUES

• FOD is becoming lodged in the transfer plate, damaging packages.
• Splices and hinge pins are wearing from the impact of heavy packages and higher-tensioned belts.
• Improperly squared belts are causing belt tracking issues that could damage the belts.

SOLUTIONS

IR/IC/NC conveyor lines are longer running lines that can have several transfer points. Flexco Segmented Transfer Plates are the perfect solution to the common problem of foreign object debris/fall-out debris (FOD) becoming lodged in transfer plates. The segmented design allows individual segments to lift, allowing the FOD to fall harmlessly through to the catch pan below.

Clipper® and Anker® Wire Hooks are quick and easy to install. High Tensile wire hooks provide superior abrasion resistance.

The Roller Lacer® Gold Class™ is the perfect tool for properly installing Clipper® and Anker® wire hooks into metro/van line conveyors.

Durastainless™ (DSS) Hinge Pins provide up to 10 times the wear life. This keeps these lines up and running during critical sortation times.

Belt tracking issues are a primary factor in lowering the overall belt and splice life on IR/IC/NC conveyor lines. Using the Laser Belt Square in these applications will significantly reduce belt tracking issues related to crooked splices caused by unsquared belt ends.

The 845LD Belt Cutter makes quick work of cutting these tough, heavy belts in a single pass.

14. Power Turn

Allows the system to make changes of direction in the line of flow. Power turn conveyors are located anywhere the conveyor system needs to make a change of direction.

ISSUES

• Fall-off debris is becoming lodged in the transfer plate, damaging packages.
• Small packages or envelopes are getting lodged in the transfers.
• Hinge pins are wearing and migrating due to the lack of flexibility around pulleys.
• Splices are wearing and failing, damaging the belt. 

SOLUTIONS

The Flexco Segmented Transfer Plate is adaptable to fit in most power turn applications. The tighter seal created by the Flexco Segmented Transfer Plate will significantly reduce the chances of FOD or small parcels getting caught in the transfer area.

Durastainless™ and Duralink™ Hinge Pins provide the extra wear protection needed in Power Turn applications. Duralink, with a cable core, is a great choice for conical pulleys found in some Power Turn applications. The cable core allows the pin to flex as it transfers around the conical shaped pulley.

15. Merge/Lateral Feed

Links conveyors that are running perpendicular or near perpendicular to each other. Merge/Lateral Feed conveyors are located anywhere they are needed throughout the system.

ISSUES

• Hinge pins are wearing and breaking due to fatigue from wrapping around pulleys.
• Wire hooks are wearing due to the abrasiveness of the packages.
• Foreign object debris/fall-out debris is becoming lodged in the transfers, damaging packages.

SOLUTIONS

Durastainless™ and DuraLink™ Hinge Pins provide the extra wear protection needed in Merge/Lateral Feed applications, especially those that are set up on a 45° angle because of the angle set on the head and tail pulleys. The flexible stainless steel cable core will allow the pin to wrap around the pulley without fatiguing and breaking. The hybrid coating also provides longer overall wear life.

Clipper® and Anker® High-Tensile Wire Hooks are quick and easy to install on these short, high-speed conveyors and provide superior abrasion resistance.

Merge/Lateral feed conveyors are often installed with minimal clearance to the conveyor they are feeding. When the gaps are large enough, a Segmented Transfer Plate utilizing a bridge segment to meet flush against the adjoining conveyor structure, may be used.

16. Lift Gate

Allows access on both sides of the conveyor when the conveyor sections are long runs. Lift gates are usually located in the IR, IC, NC line to allow people and equipment to pass through without having to go over the top of the IR/IC/NC conveyor.

ISSUES

• Hinge pins are wearing and breaking due to fatigue from wrapping around pulleys.
• Wire hooks are wearing due to the abrasiveness of the packages.
• Foreign object debris/fall-out debris is becoming lodged in the transfers, damaging packages.

SOLUTIONS

Durastainless™ and DuraLink™ Hinge Pins provide the extra wear protection needed in lift gate conveyor applications. The shorter length of these conveyors means the hinge pin and splice will see much more interaction with the pulleys than the longer conveyors in the IR/IC/NC line. The hybrid coating also provides longer overall wear life.

Clipper® and Anker® High-Tensile Wire Hooks are quick and easy to install on these short conveyors and provide superior abrasion resistance.

Flexco Segmented Transfer Plates can be used on the outbound side of the lift gate conveyor, mounted to the lift gate conveyor in a position that allows the outbound side segments to rest in the proper position on the outbound conveyor pulley in the direction of parcel flow.

17. Retractable Gate

Retractable gates are usually located in the IR/IC/NC line to allow people and equipment to pass through without having to go over the top of the IR/IC/NC conveyor.

ISSUES

• Belt splices are failing due to worn hooks and hinge pins.
• Belts are mistracking and being damaged due to improperly squared belts.
• Foreign object debris/fall-out debris is becoming lodged in transfers, damaging packages.

SOLUTIONS

Flexco Segmented Transfer Plates can be used on the outbound side of the lift gate conveyor, mounted to the lift gate conveyor in a position that allows the outbound side segments to rest in the proper position on the outbound conveyor pulley in the direction of parcel flow.

Durastainless™ and DuraLink™ Hinge Pins provide the extra wear protection needed in lift gate conveyor applications. The shorter length of these conveyors means the hinge pin and splice will see much more interaction with the pulleys than the longer conveyors in the IR/IC/NC line. The hybrid coating also provides longer overall wear life.

Clipper® and Anker® High-Tensile Wire Hooks are quick and easy to install on these short conveyors and provide superior abrasion resistance.

Belt tracking issues are a primary factor in lowering the overall belt and splice life on retractable gate conveyors. Using the Laser Belt Square in these applications will significantly reduce belt tracking issues related to crooked splices caused by unsquared belt ends.

The 845LD Belt Cutter makes quick work of cutting belts in a single pass. And is the quickest, safest, and most accurate way to cut through light-duty conveyor belts.