The Challenge
A leading warehouse automation provider approached Elmleigh seeking a skilled team to support the installation of one of their client’s flagship UK facilities. The project featured a sophisticated material handling and retrieval system, which required not only expert installation but also the in-house manufacture, integration, and commissioning of custom-built control panels.
The Teams
The Solution
The installation was delivered in four distinct phases, each tailored to the specific type of integration required. These phases were structured around the different automated material handling and retrieval technologies deployed within the system.
To achieve seamless functionality, the team integrated multiple conveyor systems with a range of material handling units. Due to the scale and complexity of the project, the client utilized four different handling methods:
- AGVs (Automated Guided Vehicles)
- Shuttles
- Forklift Trucks (FLT)
- Overhead Cranes
A key variation between phases was determined by the type of material being processed. The system was designed to manage palletized products, enabling automated insertion, storage, and retrieval for subsequent decanting. To ensure safe and accurate pallet entry, profiling stations were incorporated, verifying pallet dimensions and integrity before integration.
Each phase required its own set of control panels, which supported the functionality of the client’s Warehouse Execution System (WES) throughout the installation. These panels were manufactured in-house using free-issue parts supplied by the client. In addition, the scope included the production of E-stop control boxes and a series of remote panels strategically positioned at key intersections within the end-user’s system to ensure safety and operational efficiency. The project is still on going with futher Phases coming up, set to finish this year.
Find out how Elmleigh can support your large-scale field installation
With extensive experience in delivering complex, multi-phase projects, Elmleigh provides end-to-end solutions for automated material handling systems. From integrating conveyors with AGVs, shuttles, to FTL to manufacturing custom control panels and safety systems in-house, we ensure seamless installation and operational reliability.
Our expertise guarantees precision, safety, and efficiency at every stage of your project. Contact Elmleigh today to start the conversation on how we can support your installation needs, no project is too small or large, Elmleigh has the expertise to support you today! Call us on 01455 847045, we are here to help.