From Challenge to Success: Installing a 10-Lane Computerized Tote System

Our client presented us with a unique challenge: installing a large 10-lane tote handling system complete with elevators, shuttles, and all associated hardware, instrumentation, and controls. This would be the largest single computerized tote system the vendor had ever developed to date. Installing this system represented the first challenge—the second would be testing, startup, and commissioning.

A team of experienced riggers and millwrights worked closely with the manufacturer to lay out and erect the large stainless steel structure to exacting measurements. Omni developed a detailed plan to meet the aggressive schedule and deployed four crews to handle all control panel installations, pneumatic piping and tubing, electrical wiring, and instrument installation throughout the facility.

Three large NEMA 4X PLC control panels were positioned along with 12 pneumatic control panels. Two motorized elevators, two weigh station turntables, and a high-speed shuttle all required power and controls as well. Due to the vast quantity of pneumatic brakes and electrical positioning sensors, Omni partnered with several millwrights to expedite instrument installation.

After four weeks of installation work, we were positioned to begin pressure testing all pneumatic tubing, bump testing and checking VFDs/motors, and individually testing hundreds of pneumatic controls, electrical proximity sensors, and limit switches. Dozens of totes were then placed into the system, weighted with 50 pounds of water in place of product.

After two weeks of sequence testing, adjustment, and fine-tuning, the new computerized tote system was ready for service. Omni worked closely with the rigging team, millwrights, and electricians to make this system a working reality.

Safety Innovation

One specific challenge was working safely and efficiently throughout the installation. The team developed wooden work platforms with rails that could move along the racks, making installation much easier. This innovation eliminated the need for extension ladders and over-reaching, significantly reducing fall risks.

This project showcases Omni's expertise in handling complex industrial installations from start to finish. Our ability to coordinate multiple crews, develop innovative safety solutions, and deliver precision results on aggressive timelines makes us the trusted partner for your most challenging automation and control system projects. Contact Omni today to discuss how we can bring our proven experience to your next industrial installation.