Don’t Let Your Conveyor Slow You Down: Conveyor Upgrades for a Smoother, Faster Warehouse

Conveyor upgrades can be the key to unlocking a smoother, safer, and more efficient warehouse environment. Conveyors are the backbone of many warehouses, playing a crucial role in keeping products moving and operations running smoothly. However, as with any machinery, conveyors can age and malfunction over time, leading to inefficiencies and safety hazards.

Conveyor Upgrades

This blog post explores the reasons why upgrading aging and malfunctioning conveyors is crucial for maintaining optimal warehouse efficiency. We’ll also discuss some of the factors to consider when making the decision to upgrade or replace your conveyor system.

Problems Caused by Outdated Conveyors

Using outdated conveyors can lead to a number of problems in your warehouse, including:

  • Decreased efficiency: Older conveyors may not be able to keep up with the demands of your operation, leading to bottlenecks and delays.
  • Increased downtime: Outdated conveyors are more likely to break down, requiring repairs and maintenance that can disrupt your workflow.
  • Safety hazards: Malfunctioning conveyors can pose safety risks to your employees, such as pinch points and falling objects.
  • Higher energy costs: Older conveyors may be less energy-efficient than newer models, leading to higher operating costs.
  • Product damage: Damaged or malfunctioning conveyors can damage your products, resulting in lost revenue and customer dissatisfaction.

Conveyor Upgrades for Improved Efficiency

Upgrading your conveyors to newer, more efficient models can provide a number of benefits, including:

  • Increased throughput: Newer conveyors can handle more products per hour, which can help you meet your production goals and improve customer satisfaction.
  • Reduced downtime: Modern conveyors are typically more reliable and require less maintenance, leading to less downtime and increased productivity.
  • Improved safety: Newer conveyors often come with safety features such as guards and sensors, which can help to reduce the risk of accidents.
  • Lower energy costs: Energy-efficient conveyors can help you save money on your operating costs.
  • Reduced product damage: Modern conveyors are designed to handle products gently, which can help to reduce damage and waste.

Making the Decision to Upgrade or Replace

The decision of whether to upgrade or replace your conveyor system will depend on a number of factors, including:

  • The age and condition of your existing conveyors: If your conveyors are very old or in poor condition, they may be beyond repair and need to be replaced.
  • The capacity needs of your warehouse: If your warehouse is growing or you are planning to increase production, you may need to upgrade to a conveyor system with a higher capacity.
  • Your budget: Upgrading or replacing a conveyor system can be a significant investment. You will need to weigh the cost of the upgrade against the potential benefits.

Conveyor Upgrades with LaFayette Engineering

Upgrading aging and malfunctioning conveyors is an investment that can pay off in the long run by improving efficiency, safety, and productivity in your warehouse. By carefully considering the factors discussed in this blog post, you can make an informed decision about whether to upgrade or replace your conveyor system.

At Lafayette Engineering, we understand the importance of having a reliable and efficient conveyor system in your warehouse. We offer a wide range of conveyor solutions, from new system design and installation to upgrades and maintenance of existing systems. Our team of experienced engineers can help you assess your needs and recommend the best solution for your warehouse.

Contact Lafayette Engineering today to learn more about our conveyor solutions.

About Lafayette Engineering: Your Partner in Conveyor Solutions

Lafayette Engineering is a trusted provider of comprehensive conveyor solutions, dedicated to helping businesses optimize their warehouse operations.

Our Expertise:

  • Over 40 years of experience: We have a long history of providing reliable and innovative conveyor solutions to a diverse range of industries.
  • Turnkey services: We offer a comprehensive service package, from initial consultation and design to fabrication, installation, and ongoing maintenance.
  • Wide range of solutions: We offer a variety of conveyor types, including belt conveyors, roller conveyors, and sortation systems, to meet your specific needs.
  • Commitment to quality: We use only the highest quality materials and components in our conveyor systems, ensuring long-lasting performance and reliability.
  • Focus on safety: We prioritize safety in all aspects of our services, adhering to strict safety standards and regulations.
  • Dedicated team: Our team of experienced engineers and technicians is committed to providing exceptional customer service and support.

Why Choose Lafayette Engineering for Conveyor Upgrades?

  • Experience and expertise: We have the knowledge and experience to design and implement the right conveyor solution for your unique needs.
  • Quality and reliability: Our commitment to quality ensures that your conveyor system will operate efficiently and reliably for years to come.
  • Safety focus: We prioritize safety and provide training and resources to ensure your employees can work safely around your conveyor system.
  • Customer service: We are dedicated to providing exceptional customer service and support, from initial contact to ongoing maintenance.

Contact Lafayette Engineering today to discuss your conveyor upgrades needs and discover how we can help you achieve optimal warehouse efficiency.

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East Coast Success Story: 266K+ cartons per day

The LMS (Lafayette Magnetic Sortation)

In early 2021, Lafayette Engineering was approached by an upcoming industry leader with the request of providing a new system for meet their expanding east coast growth.  A facility capable of processing 260K cartons per day, including cartons and Polybags.   

LMS Magnetic Divert Switch

We designed and fulfilled this request.  We partnered with Eurosort for Polybags and Hytrol Conveyor for Cartons.  Together with our partners, we implemented and created a seamless flow of products from receiving, capturing weights, dimensions, and barcodes, to outbound destinations.  We implemented our LMS Magnetic Divert Switch allowing faster response speeds on the Outbound Sorters.   

LMS System

Our ConveyorWorks software team worked with the customer’s WMS to provide a custom solution supporting their on-demand technology requirements to track each package and ensuring that each Carton and Polybag successfully reaching the correct outbound destination, ensuring an on-time delivery to their customers.    

In an amazing feat, this facility opened in time for peak season and boasted an output of 266K cartons per day within the first month of becoming fully operational. Since then, this facility has continued to achieve record production numbers, surpassing the original goals and expectations.  We are honored to continue and cultivate growth with this customer and assist with them additional facilities across the U.S.   

5 Ways Conveyor Systems Can Transform Your SMB in 2024

Top Conveyor Companies

Conveyor systems can be a game-changer for small and medium-sized businesses (SMBs), offering a wide range of benefits that can transform your operations. In today’s competitive manufacturing landscape, SMBs are constantly looking for ways to improve efficiency, reduce costs, and boost productivity.

Conveyor Systems

Conveyor Systems = Increased Productivity

One of the most significant advantages of conveyor systems is their ability to increase productivity. By automating the transportation of materials and products, conveyors can eliminate manual handling tasks, freeing up your employees to focus on more value-added activities. This can lead to a significant reduction in labor costs and an overall increase in production output.

Reduced Labor Needs

As mentioned above, conveyor systems can automate many manual handling tasks, which can help to reduce your labor needs. This is especially beneficial in today’s tight labor market, where it can be difficult to find and retain qualified workers. By reducing your reliance on manual labor, you can free up your workforce to focus on more strategic tasks.

Improved Material Flow

Conveyor systems can help to improve the flow of materials throughout your production facility. This can help to reduce bottlenecks and ensure that your products are moving through the production process smoothly. Improved material flow can also lead to reduced lead times and improved customer satisfaction.

Enhanced Safety

Conveyor systems can help to improve safety in your workplace by reducing the need for employees to manually lift and move heavy materials. This can help to prevent injuries and create a safer working environment for your employees.

Customizable Solutions

Conveyor systems can be customized to meet the specific needs of your business. This means that you can find a system that is the right size and configuration for your facility and your production process.

Easy Installation and Maintenance

Conveyor systems are relatively easy to install and maintain. This means that you can get your system up and running quickly and efficiently, and you won’t have to worry about expensive maintenance costs.

Lafayette Engineering: Your Partner in Conveyor Technology

At Lafayette Engineering, we understand the unique challenges faced by SMBs. We are a dedicated team of engineers with extensive experience in designing and installing conveyor systems for a wide range of industries. We are committed to providing our customers with affordable, customized solutions that meet their specific needs.

We offer a wide variety of conveyor systems, including:

  • Belt conveyors
  • Roller conveyors
  • Overhead conveyors
  • Sortation systems
  • And more

We can also provide you with a complete range of services, including:

  • System design and engineering
  • Installation and startup
  • Maintenance and support

If you are looking for a way to improve efficiency, reduce costs, and boost productivity, then a conveyor system from Lafayette Engineering may be the right solution for you. Contact us today to learn more about how we can help you transform your business.

Additional benefits of using Lafayette Engineering:

  • Experience: We have been in the conveyor business for over 30 years, so we have the experience and expertise to handle any project, big or small.
  • Quality: We use only the highest quality materials and components in our conveyor systems, so you can be sure that you are getting a product that will last.
  • Service: We are committed to providing our customers with exceptional service, from the initial consultation to the ongoing maintenance of your system.
  • Affordability: We offer competitive prices on our conveyor systems and services, so you can be sure that you are getting a good value for your investment.

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Conveyor Systems Pallet Conveyor: LaFayette Engineering

Conveyor Systems Pallet Conveyor

Pallet conveyors are a type of conveyor system that is specifically designed to transport pallets. They are commonly used in warehouses and distribution centers to move heavy loads efficiently. Pallet conveyors can be powered or non-powered, and they come in a variety of sizes and configurations to meet the specific needs of each application.

Conveyor Systems Pallet Conveyor

Benefits of Using Conveyor Systems Pallet Conveyor

There are many benefits to using pallet conveyors in your warehouse or distribution center. Some of the most important benefits include:

  • Increased efficiency: Pallet conveyors can help you to move pallets more quickly and efficiently, which can save you time and money.
  • Reduced labor costs: Pallet conveyors can help you to reduce your reliance on manual labor, which can save you money on labor costs.
  • Improved safety: Pallet conveyors can help to improve safety in your workplace by reducing the risk of injuries to workers.
  • Increased productivity: Pallet conveyors can help you to increase your overall productivity by streamlining your material handling operations.

How to Choose the Right Conveyor Systems Pallet Conveyor for Your Needs

When choosing a pallet conveyor for your warehouse or distribution center, it is important to consider a number of factors, such as:

  • The size and weight of the pallets you will be transporting
  • The volume of pallets you will be transporting
  • The layout of your warehouse or distribution center
  • Your budget

Once you have considered these factors, you can start to narrow down your options and choose the right pallet conveyor for your needs.

Conveyor Systems Pallet Conveyor: A Versatile and Efficient Material Handling Solution

Pallet conveyors are a versatile and efficient material handling solution that can be used in a wide variety of applications. If you are looking for a way to improve the efficiency and productivity of your warehouse or distribution center, then a pallet conveyor may be the right solution for you.

Background on Lafayette Engineering

Lafayette Engineering is a multi-disciplined engineering consulting firm with over 70 years of experience. They provide a wide range of engineering services.

Lafayette Engineering is committed to providing their clients with high-quality, cost-effective engineering solutions. They have a team of experienced engineers who are passionate about their work.

How Lafayette Engineering Can Help You

If you are looking for an engineering firm that can help you with your next project, Lafayette Engineering is a great option. They have the experience and expertise to handle a wide variety of projects, and they are committed to providing their clients with the best possible service.

Here are some additional benefits of using Lafayette Engineering:

  • They have a proven track record of success.
  • They are a trusted partner to many businesses and organizations.
  • They are committed to safety and quality.
  • They offer competitive rates.

If you are interested in learning more about Lafayette Engineering, please visit their website or contact them today.

Additional information about Conveyor Systems Pallet Conveyor

  • Pallet conveyors can be powered by electricity, hydraulics, or gravity.
  • Pallet conveyors can be integrated with other material handling systems, such as cranes and robots.
  • Pallet conveyors can be made from a variety of materials, including steel, aluminum, and plastic.


Transforming Warehouse Dynamics: The 5 Powers of Automated Sortation Systems

Automatic Sortation

In the dynamic world of warehousing and logistics, efficiency and productivity are paramount. The advent of Automated Sortation Systems has brought about a significant transformation in how warehouse operations are conducted, ensuring that businesses can keep pace with the increasing demands of e-commerce and global distribution.

automated sortation systems

The Need for Automated Sortation Systems

Traditionally, warehouses managed inventory in bulk, with orders primarily consisting of pallets of goods. However, the rise of online shopping has necessitated a shift towards individual order processing, thereby complicating the sorting, packing, and shipping processes. Automated Sortation Systems have emerged as a solution to this challenge, eliminating the need for manual sorting and significantly enhancing efficiency and labor productivity.

How Automated Sortation Systems Work

Automated Sortation Systems are sophisticated material handling solutions that identify items and direct them to their designated destinations within warehousing and storage facilities. These systems leverage advanced algorithms and codes, often integrating with Warehouse Management Systems (WMS) and Internet of Things (IoT) technologies to optimize operations. By automating the sorting process, these systems reduce the reliance on manual labor, thereby minimizing errors and increasing throughput.

Benefits of Implementing Automated Sortation Systems

  1. Increased Productivity and Efficiency: By automating repetitive tasks, sortation systems allow warehouse workers to focus on more value-added activities, thereby increasing overall productivity and efficiency.
  2. Enhanced Accuracy: Automated systems minimize human errors, ensuring that orders are processed correctly, which in turn enhances customer satisfaction and business reputation.
  3. Reduced Labor Costs: Automating the sortation process reduces the need for manual labor, helping businesses to manage labor costs more effectively, especially in high-volume operations.
  4. Improved Workplace Safety: Automated systems reduce the physical and mental strain on workers, lowering the risk of workplace accidents and promoting a safer working environment.
  5. Scalability and Flexibility: Automated Sortation Systems can be scaled and adapted to meet changing business needs, making them a versatile solution for warehouses and distribution centers of all sizes.

Industries Benefiting from Automated Sortation

Automated Sortation Systems find application across various industries, including automotive, e-commerce, pharmaceuticals, and food and beverage. These systems are particularly beneficial in sectors where high-volume material handling is a critical component of operations.

The Future of Automated Sortation

The global market for Automated Sortation Systems is on a growth trajectory, with projections indicating a significant increase in market size in the coming years. This growth is driven by the continuous evolution of e-commerce and the increasing need for efficient warehousing solutions. As technology advances, the capabilities of sortation systems are expected to expand, further enhancing their efficiency and effectiveness.

Automated Sortation Systems Recap

Automated Sortation Systems represent a significant leap forward in warehousing and logistics operations. By streamlining the sorting process, these systems not only improve operational efficiency but also contribute to better workplace safety and customer satisfaction. As businesses continue to navigate the complexities of global distribution and e-commerce, the adoption of automated sortation solutions is set to become a standard practice, driving the future of warehousing towards greater innovation and efficiency.

LaFayette Engineering Role in Automated Sortation Systems

Lafayette Engineering, a prominent player in the field of material handling and automation, plays a pivotal role in the integration and implementation of Automatic Sortation Systems within the logistics and warehousing industry. As businesses increasingly seek efficient, reliable, and scalable solutions to meet the growing demands of e-commerce and global distribution, Lafayette Engineering stands out as a key facilitator in optimizing warehouse operations through advanced sortation technology.

Automatic Sortation Systems are at the heart of modern warehousing, designed to expedite the process of sorting goods based on destination, size, weight, or other predefined criteria. These systems are crucial for distribution centers, e-commerce fulfillment, manufacturing plants, and postal services, where high-volume and accurate sorting operations are essential for efficiency and customer satisfaction. Lafayette Engineering’s expertise in this domain ensures that businesses can leverage the full potential of automated sortation to enhance their operational throughput and accuracy.

Lafayette Engineering’s approach to integrating Automatic Sortation Systems is comprehensive, encompassing consultation, design, installation, and maintenance. The company’s team of experts works closely with clients to understand their specific needs, challenges, and objectives. This client-centric approach ensures that each sortation solution is tailored to the unique requirements of the business, whether it’s improving throughput, reducing errors, or enhancing overall efficiency.

One of the key strengths of Lafayette Engineering is its ability to provide end-to-end solutions. From the initial assessment of a facility’s layout and operational flow to the selection of appropriate sortation technology and its integration with existing Warehouse Management Systems (WMS), Lafayette Engineering ensures a seamless transition to automated sortation. This holistic approach minimizes disruptions to ongoing operations and maximizes the return on investment for businesses looking to modernize their warehousing and distribution operations.

Lafayette Engineering’s role in the implementation of Automatic Sortation Systems also extends to training and support. Understanding that the success of any automation project relies not only on the technology but also on the people operating it, Lafayette provides comprehensive training to ensure that staff are proficient in using the new systems. Ongoing support and maintenance services further ensure that the sortation systems operate at peak efficiency, with minimal downtime and maximum productivity.

The impact of Lafayette Engineering’s work in the field of Automatic Sortation Systems is significant. By enabling faster, more accurate sorting processes, Lafayette helps businesses to meet the ever-increasing expectations of their customers for quick and reliable delivery. This is particularly crucial in the e-commerce sector, where the ability to efficiently process a high volume of orders can be a competitive advantage.

Moreover, Lafayette Engineering’s solutions contribute to a safer and more ergonomic working environment. Automated sortation systems reduce the need for manual handling of goods, thereby lowering the risk of workplace injuries and enhancing employee satisfaction. This not only supports a healthier workforce but also aligns with broader industry trends towards more sustainable and responsible operational practices.

In conclusion, Lafayette Engineering’s role in the realm of Automatic Sortation Systems is transformative. By harnessing the power of automation, Lafayette not only enhances the operational capabilities of businesses but also drives innovation in the logistics and warehousing industry. As the demand for efficient, accurate, and scalable sorting solutions continues to grow, Lafayette Engineering’s expertise and comprehensive solutions position it as a leader in helping businesses navigate the complexities of modern warehousing and distribution.

Exploring the Lafayette Magnetic Sortation LMS System: A Revolution in Material Handling

The LMS (Lafayette Magnetic Sortation)

In the realm of material handling and sortation systems, innovation and efficiency are paramount. The Lafayette Magnetic Sortation LMS system, developed by Lafayette Engineering, Inc. (LEI), stands out as a groundbreaking solution that leverages electromagnetic technology to enhance sortation processes. This blog delves into the intricacies of the LMS system, its design principles, operational advantages, and its potential impact on the industry.

LMS System

Introduction to Lafayette Engineering, Inc. (LEI)

Lafayette Engineering, Inc. is a prominent player in the engineering and material handling industry, known for its innovative solutions and commitment to quality. The company’s latest offering, the LMS system, underscores its dedication to pushing the boundaries of what’s possible in material handling technology.

The Genesis of the LMS System

The LMS system is a testament to LEI’s innovative approach to solving common challenges in material handling. Traditional sortation systems often rely on mechanical components that are prone to wear and tear, noise, and require significant maintenance. In contrast, the LMS system uses electromagnetic technology, employing multiple magnets to create magnetic fields that precisely control the movement and sortation of items.


How the LMS System Works

At the heart of the LMS system is its use of electromagnetic technology. The system incorporates multiple magnets within the LMS switch, which generate magnetic fields. These fields are used to attract the pins and/or bearings of shoes towards a diverting path, effectively sorting items without the need for physical contact or mechanical movement. This innovative approach eliminates many of the drawbacks associated with traditional mechanical sortation systems.

Key Features and Benefits

  1. Speed and Efficiency: The LMS system boasts impressive speed capabilities, reaching up to 725 feet per minute (fpm). This high-speed sortation capability makes it particularly suitable for operations that require rapid processing of items.
  2. Maintenance and Durability: One of the standout features of the LMS system is its lack of moving components. This design choice significantly reduces the system’s susceptibility to wear and tear, lowers noise levels, and diminishes the need for frequent maintenance.
  3. Versatility: The LMS system’s design allows for seamless integration into new systems or as a drop-in unit in existing Hytrol sortation systems with minor adjustments. This versatility ensures that businesses can adopt the LMS technology without the need for extensive overhauls of their current infrastructure.
  4. Innovative Use of Electromagnetic Technology: The application of electromagnetic technology in material handling sortation is a novel approach that sets the LMS system apart from conventional solutions. This technology enables precise and efficient sortation without the mechanical complexities and limitations of traditional systems.

Impact on the Material Handling Industry

The introduction of the LMS system by Lafayette Engineering represents a significant leap forward in sortation technology. Its innovative use of electromagnetic technology not only enhances efficiency and speed but also offers a more sustainable and maintenance-friendly solution. As businesses continue to seek ways to optimize their operations and reduce downtime, the LMS system provides a compelling option that addresses many of the pain points associated with material handling and sortation.

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The Lafayette Magnetic Sortation (LMS) system is a groundbreaking innovation in the field of material handling. With its unique use of electromagnetic technology, high-speed capabilities, and low-maintenance design, the LMS system is poised to revolutionize sortation processes across various industries. Lafayette Engineering’s commitment to innovation and quality is evident in the LMS system, offering businesses a reliable, efficient, and cutting-edge solution to meet their sortation needs.

As the material handling industry continues to evolve, technologies like the LMS system will play a pivotal role in shaping the future of efficient and sustainable operations. The LMS system not only exemplifies Lafayette Engineering’s innovative spirit but also sets a new standard for what is possible in material handling technology.

For more information or inquiries about the LMS system, interested parties can reach out to Lafayette Engineering at This contact point serves as a gateway for businesses to explore how the LMS system can be integrated into their operations, marking the beginning of a new era in material handling and sortation.

The Pivotal Role of Control Systems Engineers in Modern Industry

Control Systems Engineer

Introduction to Control Systems Engineers

In the ever-evolving landscape of modern industry, the role of a control systems engineer has become increasingly vital. These professionals are at the forefront of designing, developing, and managing dynamic control systems across various sectors. Their work ensures the stability and efficiency of systems that are integral to our daily lives, from simple household appliances to complex industrial machinery.

Control Systems Engineers

Understanding Control Systems Engineering

Control systems engineering, a discipline intertwined with mechanical and electrical engineering, employs control theory to design systems that operate with minimal or zero human intervention. This field has evolved to focus primarily on binary and digital controls, with analog controls becoming less prevalent. Control systems engineers are responsible for creating systems that range from lighting and water flow controls to advanced automotive and aviation technologies.

Job Overview and Responsibilities

A control systems engineer’s job is multifaceted, involving research, design, and management of equipment that monitors and controls various systems and machinery. Their goal is to ensure safe, efficient, and cost-effective operations. Key responsibilities include:

  1. Development and Construction of Controls: Engineers design and build control systems, selecting appropriate algorithms and tools.
  2. Research and Design: They engage in extensive research to understand the processes they aim to control, often collaborating with equipment operators and designers.
  3. System Implementation: This involves purchasing ICT equipment, overseeing installation, and training personnel on system usage.
  4. Maintenance and Optimization: Engineers are tasked with maintaining existing systems and enhancing their safety, efficiency, and economic viability.
  5. Leadership: They often lead teams comprising engineers and technicians, ensuring smooth project execution.

Control System Engineers Skills and Qualifications

Control systems engineering requires a blend of technical and soft skills. Technical skills include a strong foundation in mathematics, science, and technology, along with proficiency in software like Matlab, HMI, Simulink, and PCI. Knowledge in electrical theory, robotics, and automation is crucial. Soft skills such as organizational ability, problem-solving, and effective communication are equally important. Typically, a Bachelor’s degree in engineering is required, with specializations in fields like Industrial Technologies or Computer Engineering. Advanced roles may require a Master’s degree.

The Impact of Control Systems Engineering

Control systems engineers play a critical role in various industries. Their work impacts:

  1. Manufacturing: They design systems that automate production lines, increasing efficiency and safety.
  2. Transportation: Engineers develop control systems for vehicles and traffic management, enhancing safety and reducing congestion.
  3. Energy: In the energy sector, they create systems that optimize the use and distribution of energy resources.
  4. Healthcare: They contribute to the development of medical devices and hospital management systems, improving patient care.

Challenges and Opportunities

The field of control systems engineering is not without its challenges. Keeping pace with rapid technological advancements, managing complex projects under tight deadlines, and ensuring system security are some of the hurdles these professionals face. However, these challenges also present opportunities for innovation, career growth, and significant contributions to technological progress.

Southern Conveyor Systems


Control systems engineers are the unsung heroes of the modern industrial world. Their expertise in designing and managing complex systems plays a crucial role in enhancing the efficiency, safety, and sustainability of various industries. As technology continues to advance, the demand for skilled control systems engineers is set to grow, making this field an exciting and rewarding career choice.

Lafayette Engineering: A Leader in Sortation Systems

Sortation Systems

In the dynamic world of material handling and warehouse operations, Lafayette Engineering stands out as a leader in providing advanced sortation systems. Sortation, a critical process in modern logistics, involves identifying individual items on a conveyor system and accurately diverting them to their designated locations. This process is facilitated by a range of devices, all controlled by specialized software, ensuring efficiency and precision in handling materials.

One of the most significant hurdles businesses encounter in the journey of delivering their products to the market is product sortation. Sortation systems play a crucial role in this process by dividing products into distinct lanes, each corresponding to a specific outbound destination. To create an effective material handling solution, various kinds of sortation and conveyor systems are integrated, working in unison to streamline the distribution process.

The Essence of Sortation Systems

Sortation systems are integral to various stages of warehouse operations, including receiving, picking, packing, and shipping. These systems not only enhance the sorting rate but also significantly reduce error levels, contributing to overall operational efficiency.

The importance of precise and timely order fulfillment has reached unprecedented levels in today’s market. This urgency, coupled with the need to minimize resources and cut costs in the distribution process, underscores the value and efficiency that automated sortation systems bring. In the era of booming e-commerce, these systems have transitioned from merely moving cases for retail restocking to managing a diverse array of items and packaging types, such as cases, totes, and polybags. This shift has brought about new complexities in order fulfillment, necessitating:

  • Enhanced throughput to match the surge in order volumes and the diversity of SKUs.
  • Refined order accuracy to reduce the need for processing returns.
  • The development of efficient cross-docking techniques to reduce storage and handling demands.
  • Seamless integration with warehouse execution systems for heightened automation.

Types of Sortation Systems

Lafayette Engineering offers a comprehensive range of sortation solutions, catering to different needs and applications:

  1. Case Level and Unit Sortation: These systems are designed to handle different types of products and rates, ensuring versatility in operations.
  2. Linear and Loop Sortation Systems: These include a variety of technologies, each suited to specific operational requirements.
Advanced Sortation Solutions

Advanced Sortation Technologies

Our portfolio includes an array of advanced sortation technologies:

  • Narrow Belt Sorter
  • Pusher and Paddle Sorters
  • Pop-Up Wheel Sorters
  • Shoe Sorters
  • Bombay, Cross Belt, and Tilt Tray Sorters
  • Pocket Sorters and Garment-On-Hanger (GOH) Systems
  • Autonomous Mobile Robots like TiltSort-Bot and Hi-Tilt-Bot
  • Innovative Putwall and Robotic Putwall Systems

Application in Distribution Centers

Sortation systems from Lafayette Engineering find extensive application in:

  1. Receiving: Facilitating efficient return processing and putaway.
  2. Picking: Enhancing order fulfillment and reducing cycle times.
  3. Packing: Streamlining the consolidation of orders.
  4. Shipping: Optimizing the shipment process for various carrier methods.

Why Choose Lafayette Engineering?

With over three decades of experience in designing and implementing high-speed sortation systems, Lafayette Engineering is at the forefront of this technology. Our solutions are tailored to meet the unique needs of our clients, ensuring the best fit for their operational requirements.

Considerations for Implementing Sortation Systems

Before integrating a sortation system, it’s crucial to consider:

  • The nature of items to be sorted (fragility, variety, geometry)
  • Required sorting rate and noise levels
  • Available space and footprint
  • Packaging materials needed


Lafayette Engineering’s commitment to innovation and excellence in sortation systems makes us a trusted partner in enhancing the efficiency and accuracy of your warehouse operations. Our expertise in designing and implementing custom solutions ensures that we deliver the best sortation system for your specific needs.

Enhancing Warehouse Efficiency with Pick and Pass Zone Routing Conveyors – A Perspective for Lafayette Engineering

The Pick and Pass Zone Routing Conveyor System

In the realm of warehouse automation, the Pick and Pass Zone Routing Conveyor system represents a significant leap in efficiency and productivity. This system is designed to optimize the ‘person to product’ material handling concept, where order selectors travel to pick locations to gather products. The system’s primary goal is to reduce unnecessary movement (deadheading) and increase the productivity of operators.

Introduction to Lafayette Engineering

Lafayette Engineering, a leader in industrial automation solutions, specializes in conveyor systems and controls. Their expertise in streamlining production processes through innovative technology makes them a key player in the industry. Understanding the intricacies of conveyor systems, Lafayette Engineering is well-positioned to appreciate the advancements in warehouse automation, particularly the Pick and Pass Zone Routing Conveyor system.

How Does Zone Routing Work?

The Pick and Pass system is a sophisticated conveyor setup that intelligently routes shipping cartons or order totes through a pick system to the exact zones where work is located. The process involves several key steps:

  1. Induction of Containers: Cartons or totes are introduced into the picking area from other zones or a centralized point.
  2. Travel and Scanning: The container travels along a conveyor towards a pick zone transfer, where it is scanned to identify its destination.
  3. PLC and WES Interaction: The barcode information is sent to a Programmable Logic Controller (PLC), which interfaces with the Warehouse Execution System (WES) to determine the container’s next destination.
  4. Order Processing: Operators in the pick zone process the container by fulfilling the required picks, guided by the Warehouse Management System (WMS) or WES.
  5. Return to Conveyor: Once the picks are completed, the container is returned to the central conveyor for further routing.

Benefits of the System

The Pick and Pass system offers several advantages:

  • Reduced Deadheading: By eliminating movement through zones with no required picks, it enhances operational efficiency.
  • Targeted Order Placement: Orders are automatically directed to zones where picks are needed, streamlining the process.
  • Ergonomic Handling: The system is designed to minimize physical strain on operators.
  • Seamless Integration: Interfaces with WMS and WCS ensure smooth operation and tracking of orders through the system.

Lafayette Engineering’s Role

For a company like Lafayette Engineering, the integration of Pick and Pass Zone Routing Conveyors into their conveyor solutions portfolio could be a game-changer. Their expertise in conveyor systems and controls can be leveraged to implement these advanced systems in warehouses, enhancing their clients’ operational efficiency. The system’s ability to integrate with existing WMS and WCS aligns perfectly with Lafayette Engineering’s focus on customized, high-quality solutions.


The Pick and Pass Zone Routing Conveyor system represents the future of warehouse automation, offering unparalleled efficiency in order selection and material handling. For Lafayette Engineering, adopting this technology could further solidify their position as a leader in industrial automation, providing their clients with cutting-edge solutions to meet the evolving demands of warehouse management.

The Evolution of Efficiency – Print and Apply Label Systems in Modern Industry

Print and Apply

The Emergence of Print and Apply Label Systems

In today’s fast-paced industrial landscape, efficiency and accuracy are paramount. This is where Print and Apply Label Systems come into play, revolutionizing the way businesses handle product labeling. These systems combine the processes of printing and applying labels into one seamless operation, significantly saving floor space and improving control over variable data on each product.

Print and Apply

Introduction to Lafayette Engineering

Lafayette Engineering, a dynamic player in the industrial automation sector, has been at the forefront of providing innovative solutions to streamline production processes. With a focus on conveyor systems and controls, their expertise lies in enhancing operational efficiency and productivity for various industries. Their commitment to delivering high-quality, customized solutions makes them an ideal subject for discussing the integration and benefits of Print and Apply Label Systems in modern manufacturing and distribution environments.

Understanding Print and Apply Label Systems

A Print and Apply Labeling System is an amalgamation of a label printer and a label applicator. This system is particularly beneficial for products or cartons requiring specific information like lot numbers, expiration dates, and shipping addresses. The key components of these systems include:

  1. Print Engine: A robust, high-speed printing module designed for industrial use, capable of enduring harsh production environments.
  2. Label Applicator: This component accurately places labels on containers.
  3. Programmable Logic Controller (PLC): It controls both the printer and applicator, interfacing with the operating technology system to manage label formatting and data generation.

Print engines in these systems are not your average office printers. They are designed for continuous operation in challenging environments. Brands like Zebra and Sato offer engines with varying specifications to suit different label sizes and print quality requirements. The printing technologies used are primarily:

  • Direct Thermal Printing: Ideal for short-term applications like shipping labels, using heat-sensitive paper.
  • Thermal Transfer Printing: Suitable for long-term legibility requirements, this method uses a heated print head to melt ink from a ribbon onto the label.

Label Application Techniques

The label applicator typically employs a tamp/blow method, where the label is held by a vacuum on a tamp and then applied to the container using a blast of air. This method adapts well to varying product loading speeds. Other methods like merge or air blow are also used depending on specific requirements.

Addressing Industrial Needs

Print and Apply Label Systems are designed to address two primary industrial challenges:

  1. Balancing Printing Speed with Product Loading Variations: A loose loop system creates a buffer for labels, allowing for consistent application despite varying product speeds.
  2. Flexibility in Label Usage: A web bypass feature enables the use of pre-printed labels without passing them through the print engine, maintaining high throughput.

Connectivity and Control

Modern Print and Apply Systems offer diverse connectivity options, including serial, parallel, Ethernet, USB, and wireless communications. This versatility ensures seamless integration into existing production lines, allowing for efficient control and data transmission.

Conclusion: The Role of Lafayette Engineering

Incorporating Print and Apply Label Systems aligns perfectly with Lafayette Engineering’s ethos of enhancing efficiency and productivity in industrial settings. Their expertise in conveyor systems and controls can be leveraged to integrate these labeling systems into existing production lines, offering clients a streamlined, efficient, and error-free labeling process. As industries evolve, the collaboration between innovative solutions like Print and Apply Label Systems and industry leaders like Lafayette Engineering will continue to drive the future of manufacturing efficiency.