IBT, Inc.

Systems Integrator: IBT Inc. (Merriam, KS)

IBT's distribution center integrates 14 different conveyor models for peak performance and productivity.

Versatile and diversified — this is IBT Inc. The Merriam, Kansas-based company is not only a major distributor of industrial products, but also a distributor and integrator of Hytrol Conveyor equipment. The synergy between these two aspects of the business is on full display at IBT's corporate headquarters and Central Distribution Center (CDC) in Merriam.

This center supports a network of 48 branches in 11 states for this national distributor. Many of IBT's product lines are handled here. The product lines include bearings and power transmission products, industrial rubber equipment, industrial drives and controls, and industrial automation products. The company also offers a full-service video and new media production service.

Another core business is conveying and warehousing equipment. IBT is a distributor of Hytrol conveyors as well as an experienced systems integrator. This expertise is clearly evident in the CDC, which incorporates more than 14 different Hytrol models — all seamlessly integrated for reliable performance and high productivity.

"This is not only a working system that efficiently moves products through the warehouse, but also a showcase for the capabilities of Hytrol conveyor equipment," says Charles Ensminger, marketing manager for IBT's Conveyor Equipment Group. Customers can visit the CDC to see first-hand how their products will be handled and conveyed. And companies interested in upgrading their own conveyor capabilities can get a real-world view of how Hytrol equipment might be put to use in their own operations.

Fully Integrated System

Product flows reliably and efficiently through the 95,000-sq. ft. Central Distribution Center. The order-fulfillment process begins in the four main picking zones. Using hand-held RF units, order pickers pick from 37,000 lineal feet (or about seven miles) of shelving in the picking areas. The products are picked into totes.

The totes move out of the picking zones on takeaway conveyors comprised of live roller (190-LR) and minimum-pressure accumulation (190-ACZ) segments. The takeaway lines lead to two different types of incline horizontal belt conveyors. (IBT actually makes the belts for these units in its belt and hose fabrication shop). Up the incline from Picking Zones 1 and 2 a live roller curve feeds a zero-pressure accumulation conveyor (190-SPEZ). From Zones 3 and 4 the totes move onto a 190-ABEZ accumulation conveyor.

The 190-SPEZ accumulation line that connects with Picking Zones 1 and 2 illustrates how IBT spotlights the different conveyor capabilities. The first part of the line has the original EZ Logic accumulating system. It leads into a "Generation II" 190-SPEZ segment that features enhanced control and operating features. In both cases, Hytrol's unique EZ Logic system senses product presence and effectively controls the accumulation and release of product from zone to zone.

The two accumulation lines (190-SPEZ and 190-ABEZ) run in parallel toward two roller bed declines that move the totes into the packing area. These declines are new roller bed models (190-RBI), giving visitors an opportunity to see one more option for moving product up or down.

The totes move down the roller beds and onto parallel accumulating conveyors with the EZ Logic feature. Built into one of these units is a pop-up chain transfer device that moves the totes to the packing stations. After the totes are emptied, they are placed on a slider belt conveyor and accumulation unit and before being automatically loaded on a continuously moving overhead system. The totes are returned to the picking zones, where the order-fulfillment process starts all over again.

After the orders are checked and packed, they are placed in boxes on carousels and then transferred onto a chain-driven live roller (20-CR) with a 30-degree powered spur. With a photo eye controlling the process, the spur inducts the completed orders onto a circulation loop with powered turntables on either end. When the cases arrive at the right staging area for the branch offices, they are taken off the line and staged for palletization and shipping.

Control is the Key

Approximately 40,000 orders move through IBT's Central Distribution Center every month. The flow is streamlined and efficient thanks to tight integration of the various conveyor types and the sophisticated controls in place. IBT developed the control system, which is housed in a control panel located in the packing area. Within this 5- by 6-foot two-door panel are the starters, PLC, and electrical communications that manage the flow of product throughout the facility.

Visitors are impressed with the controls and the operation overall. "Both current and potential customers like what they see here," says IBT's Ensminger. "If they want to run their products through some sample runs, that's no problem. Or if they're looking to upgrade their own conveyor capabilities, this is the perfect place to see a wide range of Hytrol equipment in action."

Two years ago IBT celebrated its 50th anniversary — a period marked by steady growth and innovation. With a solid conveyor system as a foundation, the company is confident that those positive trends will continue for the next 50 years.

IBT's Central Distribution Center

The order-fulfillment process begins in the four main picking zones. After picking is completed, live roller and minimum-pressure accumulation conveyors move the totes to the incline conveyors. The line between Picking Zones 1 and 2 feeds into a zero-pressure accumulation conveyor (190 SPEZ) with the EZ Logic feature. The line between Zones 3 and 4 merges with an ABEZ conveyor, also with EZ logic. The totes move on parallel lines down a roller bed decline and into the packing area. The orders are packed and placed in boxes on carousels and then transferred to chain-driven live roller and 30-degree powered spur, which moves the full cases onto the circulation loop. When the cases reach the correct staging area for the branches, they are taken off the line and palletized for shipping.

1-4. Picking zones
5. Live roller/minimum pressure takeaway conveyors
6. Incline conveyors
7. EZ Logic accumulating (190-SPEZ and 190-ABEZ)
8. Roller bed decline
9. Packing area
10. 30-degree powered spur
11. Circulation loop
12. Turntables

Snapshot of the Operation

Company: IBT Inc.
Facility: Central Distribution Center
Location: Merriam, KS
Size: 125,000 square feet (95,000 Warehouse, 30,000 Office)
Employees: 120
Product handled: Bearings and transmission products, and other industrial products
Throughput: 40,000 orders a month (avg.)
Pallet Bays: 4,000
Types of conveyors (Click on links below to see a video of the model as it is used in the facility): Models include 190-ACZ, 138-ACC, 190-ACC, 190-LRC, 190-SPEZ, 190-ABEZ, 20-CR, 20-CRS, TA, SBI, RBI, powered turntable, through frame transfer, pop-up roller stop, overhead pusher
Controls: PLC-based, developed by IBT
Open Shelf Space: 37,000 lineal feet
Conveyor supplier: Hytrol Conveyor Inc., Jonesboro, AR
Systems Integrator: IBT Inc., Merriam, KS