Warehouse Conveyor Expansion Project

Loadex expanded an existing conveyor network to support increased order volumes. The project was executed in phases to ensure continuous warehouse operation during installation.

Industry:
Warehousing & Logistics
Location:
Lyon, France
Year:
2025
Scope:
System expansion, integration, commissioning

Project Overview

The Warehouse Conveyor Expansion Project was initiated to increase material handling capacity within a rapidly growing distribution center. Rising order volumes and seasonal demand peaks required an upgraded conveyor infrastructure capable of improving throughput without disrupting ongoing operations.

Loadex designed and implemented a scalable conveyor expansion that enhanced sorting efficiency, reduced bottlenecks, and supported future automation integration.

Project Challenge

The client faced several operational challenges:

  • Increasing daily order volumes
  • Congestion at sorting and outbound zones
  • Limited floor space for expansion
  • Need for minimal operational downtime during installation
  • Requirement for future automation compatibility

The existing conveyor network was insufficient to meet new performance targets, leading to delays and inefficiencies.

Our Solution

Loadex engineered a phased conveyor system expansion that seamlessly integrated with the existing infrastructure. The design focused on improving flow distribution, optimizing routing logic, and increasing handling speed while maintaining safety and system stability.

Key Components Included:

  • High-speed motorized roller conveyors
  • Automated sorting modules
  • Diverter and merge systems
  • Elevated conveyor bridges for space optimization
  • PLC-based control system integration
  • Safety sensors and emergency stop systems

The expansion was implemented in controlled stages to ensure uninterrupted daily operations.

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