Parcel Handling Design and Integration
Multi-site Updates in the Western US for OnTrac
CLIENT
OnTrac
INDUSTRY
Parcel Handling
PROJECT SCOPE
System Integration, Engineering Design, Millwright/Mechanical & Electrical (Infrastructure), Controls, Project Management
Article Summary: OnTrac and SilMan, A Trusted Partnership
Built on a foundation of long-standing trust, the executive teams at OnTrac and SilMan Industries collaborated on a high-stakes challenge: to create a plan for rapid design and execution of system updates and expansions across multiple sites. To meet the aggressive timeline, SilMan proposed an innovative cost-plus strategy designed to dramatically accelerate the scheduling, design, and implementation phases for the complex, overlapping projects. This approach leveraged OnTrac’s prior positive experience with SilMan’s detailed, transparent accounting and reporting practices, ultimately proving that mutual trust in a cost-plus arrangement yields significant efficiencies and savings for both organizations.
This article recounts the results achieved through a dynamic partnership, including a detailed case study of the Redlands, California facility.
Optimizing Parcel Throughput
When parcel and logistics providers face escalating demands, their infrastructure must evolve quickly, reliably, and cost-effectively. For the OnTrac Redlands, California facility, the requirement was clear: implement a high-capacity 6K Manual Sort System that could serve dual roles, acting as both a last-mile delivery center and an auxiliary hub to manage overflow from the neighboring regional sortation center during peak seasons.
Not only did this undertaking demonstrate the prowess of SilMan’s system design and integration team, but it also showcased the company’s capability to deliver a complete, turnkey service. From the initial engineering through final commissioning, SilMan’s team approach was on full display—investigative, experienced, connected, and focused on achieving the best outcome. This parcel industry savviness provided superior control over the project’s budget, schedule, and quality, ensuring a safe, reliable, and cost-effective system built for the long term.
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For more information about this project or related topics, contact David by email or call directly at 510.409.6567.
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Strategic Engineering and Turnkey Execution
The success of a project of this scale hinges on early alignment and meticulous planning. SilMan’s process began with a deep collaborative engagement, establishing a shared vision with the client’s team. This initial phase, detailed in the project proposal, included a crucial site visit at Redlands and focused meetings with key OnTrac operations personnel, forming the foundation of the final design.
The project then moved into SilMan’s in-house engineering team:
This upfront investment in collaborative engineering and self-performed services allowed the project to transition from concept to construction with uncommon speed and efficiency.
Click images for full-screen viewing. (Photos: SilMan Industries)
System Design, Integration, and Implementation Overview
The overall directive included two aspects. First, to provide a primary design of the local delivery center while providing infrastructure for cross-dock hub operations that could absorb overflow from the OnTrac Ontario, CA Sort Center. The design must also include a separate Incompatible Conveyor System to handle ICs during hub sort operations. The challenge for the SilMan design team, in collaboration with the OnTrac engineering group, was to meet the building’s limitations and achieve the volume that OnTrac expected from the facility.
And of course, all this was accomplished within the desired budget and start-up schedule.
Highlights of the completed system include:
Value-Added: Tenant Improvement Services That Elevate Facility Performance
SilMan’s core competency in self-performed installation allowed the project to extend far beyond the material handling system, providing significant added value by tackling crucial Tenant Improvement (TI) work. This comprehensive approach eliminated the client’s need to contract and manage additional subcontractors for electrical and facility construction tasks, drastically simplifying project management and reducing schedule risk—a critical advantage in a fast-track project.
The scope for the work began with foundational support for the facility’s technology and climate control. For the new IT Room, SilMan installed specialized anti-static flooring and two fire-rated plywood panels to create a secure, compliant environment for sensitive equipment, powered by five dedicated circuits and pre-cabled with four conduits. Additionally, SilMan supplied and installed the necessary electrical and mechanical hookups for a climate control system, ensuring the IT infrastructure remained within optimal operating temperature. And finally, the installation of a security entrance at the building’s main entrance.
In the warehouse, SilMan’s electrical expertise ensured all support infrastructure was ready for operation, including the installation of two high-capacity circuits with twist-lock plugs for the Extendo telescoping conveyors, located at loading doors. The team also established the Intermediate Distribution Frame (IDF) location, running four separate circuits Above Finished Floor (AFF) at warehouse columns. Finally, SilMan enhanced the dock amenities by installing two dock fans and two dock lights, alongside new quad and convenience outlets, ensuring optimal safety and working conditions.
Electrical Infrastructure
Security Entrance
Networkwide Excellence in the Western US
The cost-plus arrangement between SilMan and OnTrac significantly influenced the multi-site approach by providing complete transparency for all costs, enabling the projects to commence much sooner than the traditional RFP process, which could have added months. In turn, the multi-year, multi-site package was completed on schedule and within budget, providing all the required functionality expected by the OnTrac executive team.
In fact, the SilMan-OnTrac collaboration completed the projects outlined below within a three-year period.
SilMan Industries’ capabilities as a fully vertical, turn-key integrator produced these outcomes through their abundant in-house resource base, encompassing mechanical and controls engineering, as well as on-site installation and project management. All these project disciplines came from our in-house resources and ability to scale quickly to meet OnTrac’s project requirements.
Project Highlights
Carlsbad, CA – New 6K Delivery Center (Completed December 2021)
- 5 Unload Doors (expandible to 6)
- 4 Way Split Sort Slide System
- 3 Van Lines – 96 Van Positions
- Hybrid Cross Dock Load Door Capability – 9 Low Volume Load Doors
Petaluma, CA – New 2K Delivery Center (Completed March 2022)
- 2 Unload Doors (expandible to 3)
- 2 Way Split LVD Sort Tower
- 2 Van Lines – 80 Van Positions
San Diego, CA – New 6K Delivery Center (Completed January 2023)
- 6 Unload Doors
- 5 Way Split Sort Slide System
- 4 Van Lines – 124 Van Positions
- Hybrid Cross Dock Load Door Capability – 7 Low Volume Load Doors
Buckeye, AZ Hub Sort Center Expansion (Completed November 2022)
- 3 Unload Doors Added
- Expanded three 3 HVD Sort Towers
- 1 Van Line – 30 Van Positions Added
- 6 Door HVD Load System
Vancouver, WA 9K Sort Center Expansion (Completed March 2022)
- 1 Outbound HVD Added
- 1 Inbound HVD Added
Conclusion: A Partnership Designed for Long-Term Success
The Redlands High-Capacity Manual Sort System is a powerful demonstration of how trust accelerates efficiency. This partnership’s transparency opened the door to Time-and-Material contracts, establishing a productive, cost-effective course of action for both parties.
From the initial proposal through to the final system manuals, SilMan acted as the single-source resource for design, engineering, management, and labor. This capacity—fueled by a curious, collaborative culture—provided OnTrac with complete control over the budget, schedule, and quality of outcomes.
By expertly managing the integration of both SilMan-provided and owner-procured equipment, the project achieved a seamless, fast-track start-up. The successful outcome of these projects solidifies the OnTrac network, with capacity for continued growth.
SilMan remains committed to OnTrac’s success by providing lifecycle support and deepening the partnership for the long term.
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.
Optimize Your Investment
SilMan’s multi-disciplinary Specialty Trade Services (STS) is a community of project professionals: Engineers, Project Managers & Coordinators, Trade Teams, and Safety Management. Bringing a new performance standard throughout the industrial community:
STS commonly supports the SilMan System Integration group. Specializations include 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.
Check out SilMan’s “One Team” approach in action: Facility improvements and a new bottling line at a leading West Coast dairy.
