Interroll Portec Belt Curve Installation
CLIENT
Levi Strauss & Co.
PROJECT SCOPE
Engineer, Material Handling Solutions, Mechanical/Millwright and Electrical, Project Management; Install Interroll-Portec Curves at two locations; reverse engineer existing mechanical, electrical, and controls
INDUSTRY
Distribution & Fulfillment
LOCATIONS
Hebron, Ky., Canton, Miss.
SilMan Material Handling engineered, procured, and installed the Interroll-Portec Belt Curve solution at two Levi Strauss & Co. facilities in the Southeastern United States.
Creative Material Handling Solutions
Repair or Replace?
This unique project puts the SilMan Engineering team in the spotlight for their careful analysis of a facility that on the surface, appeared to only require repair.
After a breakdown of a key legacy Portec curve inducting the main shipping sorter, SilMan engineer Ian Fulton made an onsite visit to assess the situation.
A temporary “fabricate and rebuild” was performed in the field by the SilMan Site Services group and the line was operational within four days. Nonetheless, the disruption was cause for concern for the client, who requested a systemwide rehabilitation project for their existing power belt curves.
However, in the process of the repair, and by Fulton’s sharp eyes during his visit, he saw the potential for a much greater outcome for only a modicum increase of investment.
The Tupelo team prepared a plan to provide Levi with an updated system – new equipment – with no downtime.
A “new versus repair” scenario was presented to the client.
The value was clearly in favor of update, which included additional benefits of OEM warranty, availability of replacement parts, reduced downtime, and, of course, the speed and reliability of new equipment.
This course of action – new Interroll-Portec curves to replace the existing curves – was embraced by Levi Strauss and executed by SilMan. The projects were cumulatively completed three weeks ahead of schedule.
The TheTThe Interroll-Portec Belt Curve
Interroll Belt Curves, also known as “Portec Curves,” are an industry-leading conveyance solution. In fact, their products can be found in 80% of all airports in the world, according to their website.
Their reputation for low maintenance and continuous-use performance made Portec Curves the perfect equipment choice for updates at the two Levi Strauss Southeastern DCs.
Speak to a key team member on this project
Meet David Rebata
For more information about this project or related topics, contact David by email or call directly at 510.409.6567.
You may also enjoy this article
Engineering Challenges
The projects were completed on multiple weekends and included two hours of system start-up each Monday after weekend work. A total of 28 curves were installed at the two facilities over 10 weekends.
Since new curves are being interpolated into a system based on the mechanical, electrical, and control parameters of outdated equipment, the most important aspect of this project was the preplanning and foresight of our engineering team.
The previous conveyor belt curves were over 20 years old. Since that time, the dimensions, power, and control specifications for the equipment have all changed, and spare parts from the OEM were almost non-existent.
Therefore, the task for our Engineering team was to “reverse engineer” the facility, equipment, electrical, and controls to receive the new power belt curves.
The primary objective throughout the implementation phase was to ensure that the client would not require any updates to elevated support structures, conveyor supports, or electrical infrastructure.
Photo Gallery
Close-up views of Interroll Portec Curves during installation.
Equipment and Controls Implementation
Mechanical
The mechanical challenge for this project was minimizing modifications of existing lines for new dimensions, and adapt existing equipment supports for the new Interroll belt curves.
Moreover, approximately 45% of the curves were positioned overhead, requiring additional engineering to ensure that all new equipment can be supported by existing hangars.
Electrical & Controls
Similar to the situation above, the electrical and controls challenge was to match new equipment with existing controls, including horsepower, speed, motor sizing, and location, all utilizing existing electrical infrastructure and controls hardware.
Onsite Efficiency: Scheduled versus actual
- Hebron: Seven estimated weekend mobilizations: Actual = Two
- Canton: Six estimated weekend mobilizations: Actual = Three
ROI Justification
New Interroll Portec Curves Deliver Value
The overriding strategy of this project was to provide a cost-sensitive solution for improved performance and reliability of the systems in these two facilities. Specifically, to include replacement of belt-curves. This tactic required that our engineering team utilize existing structural and electrical infrastructure, as a cost-saving measure.
Deriving maximum value from Portec curves begins at installation, especially when retrofitting into an existing system.
It is in situations such as this where SilMan’s veteran material handling team is uniquely valuable. Their foresight in the planning and design stages was a key element in providing maximum value for Levi and SilMan. That is the timely completion of the project and providing the efficiency and financial outcome desired by Levi Strauss.
Our experience with Interroll-Portec products also played an important role in providing a realistic ROI justification in the proposal stage.
Lastly, we cannot speak of “Results” without calling attention to the exceptional work of our execution team. Their planning and skill delivered high-quality work, and their efficiency wrapped these projects a total of three weeks (weekends) ahead of schedule.
Key Players on this project include:
- David Rebata: Account management
- Ian Fulton: Engineering
- SilMan Specialty Trade Services
We are especially grateful for the personal dedication and leadership displayed onsite by Todd Sadler and Xavier Williams.
This outcome is a great example of the “one-team” approach that is at the heart of SilMan’s organizational structure and philosophical mindset. This focus delivers efficiency through seamless communication and high-level performance through inter-discipline knowledge sharing.
The SilMan System Integration team works hand in hand with our in-house Specialty Trade Services to implement material handling solutions in a wide variety of industries, including distribution center optimization for the Fulfillment and Parcel sectors (see “A Comprehensive Guide to Efficient Parcel Handling Systems”), food and beverage manufacturing and warehouse solutions, and end-to-end innovative manufacturing solutions.
About Portec & Interroll
Founded in the 1950s, Portec developed a revolutionary conveyor design, built on flexible belts and direct-drive motors. Their products were adopted around the world, managed from their headquarters in Cañon City, Colorado.
According to their LinkedIn page, Portec systems originally installed in the 50s are still in operation.
The company was acquired by Interroll in 2013.
The hands-on craftsmanship behind the quality and longevity of the equipment is clearly alive and well, as seen in this video, which features “behind-the-scenes” footage captured at their manufacturing facility.
Interroll is a material-handling manufacturer based in Sant’ Antonino, Switzerland. Originally launched in 1959, the company expanded its international footprint in the 1960s and 1970s by acquisition.
Since that time, Interroll has emerged as an innovator in the field of conveyors, sorters, controls, and automation.
With the addition of the Portec products, Interroll has emerged as the leading global supplier of conveyor equipment for baggage handling systems and eCommerce Fulfillment.
About the Company
SilMan Industries (previously SilMan Construction) is based in San Leandro, Calif., with Engineering and Field Operations offices in Tupelo, Miss. The firm provides integrated turnkey solutions in the Industrial, Manufacturing, Distribution, and Public Works sectors.
Notably, in 2010 SilMan Industries was contracted to dismantle and remove the NUMMI assembly line in Fremont, Calif., transport the equipment, and reinstall the system in Blue Spring, Miss., establishing Toyota Motor Manufacturing Mississippi (TMMMS). This high-visibility project ignited the company’s meteoric growth, laying the foundation for SilMan’s national service area.
For more information, please visit www.silmanindustries.com/about.
