Conveying & sorting
Conveyors play an important role within intralogistics systems. They supply and interconnect areas used for storage and picking, or for production and assembly. KNAPP has an extensive portfolio of conveyor systems that are tailored to a wide range of requirements. The classic conveyor system Streamline, for containers, cartons and trays, together with Powerline, for pallets, are ideal for high-performance applications. Flexible and powerful overhead conveyor systems bring new momentum to warehouse processes, particularly when combined with the innovative Sorter Pocket. Solutions using the Sorter Pocket are especially well-suited for use in e-commerce, omni-channel applications, fashion and production.
With the free-moving, intelligent Open Shuttles, KNAPP is in pole position in the field of driverless transport systems and is opening up new dimensions in flexible warehouse processes. Special solutions such as the puck conveyor system top off the KNAPP group’s portfolio.
The KNAPP group also offers various solutions for sorting and sequencing shipments efficiently, such as the OSR Shuttle™ Sorter, the innovative Sorter Pocket or the Split Tray Sorter.
All-in-one conveyor system
Streamline is the KNAPP group’s container and carton conveyor system. The conveyor system handles important tasks in an intralogistics system, serving as the main artery of the warehouse and supplying the right goods to wherever they are needed. Streamline is an all-in-one conveyor system containing both mechatronic components and control elements, and comes in roller conveyor and belt conveyor designs.
High versatility
Streamline is used for a variety of applications throughout order fulfilment and distribution centres.
| Load carriers | Containers, trays, cartons, soft packaging |
| Weight of transport object | Up to 50 kg |
| Load carrier outer dimensions | 180 x 180 mm bis 850 x 850 mm |
| Performance | Up to 3,500 load carriers per hour |
The individual Streamline components are available in different designs, varying in nominal width, roller pitch, etc.
Modular design
Streamline is modular in design, using component building blocks that share common parts. There is at least one component available for each logistical function, such as a roller conveyor, belt conveyor, transfer element or elements for handling transport goods. The modular system delivers maximum scalability; therefore, Streamline can be precisely adapted to size and investment. KNAPP relies on high quality standard parts and works together with well-known suppliers to bring you Streamline.
A hybrid drive concept with a three-phase asynchronous motor drive unit and a motorized roller drive unit ensures optimal performance. A tried and tested AS-i bus system acts as the Streamline control technology, allowing components to be connected easily and economically. The AS-i bus system forms the basis of the intuitive full visualization with KiSoft SCADA. KiSoft SCADA visualizes everything up to actuator-sensor level and ensures maximum availability. KiSoft SCADA also provides additional support during maintenance. Streamline is easy to maintain, which saves time. Access from above means that all components can be replaced quickly. Rollers with clasps and modules that can be replaced as a whole also contribute to keeping maintenance simple.
Advantages of Streamline
- Maximum performance: throughput of up to 3,500 containers, trays or cartons per hour
- Hybrid drive unit: maximum performance with minimum noise using the three-phase asynchronous motor drive unit and motorized roller drive unit
- Smart control system: tried and tested AS-i bus system connects components simply and economically; intuitive full visualization of everything up to the individual sensors and actuators with KiSoft SCADA
- Process innovation: fast installation and startup thanks to a modular system and a high degree of pre-assembly
- Quality: proven technologies ensure maximum quality
- Energy efficient: maximum availability and performance with minimum energy consumption thanks to the revolutionary accumulation stop concept
- Easy maintenance: rollers with clasps; replacement of entire modules and assemblies; stream-lined spare parts management thanks to parts commonality
Efficient processes for pallets
Powerline is the KNAPP group’s pallet conveyor system. It forms the basis of efficient processes and is 100 % in tune with the demands of modern logistics centres. Maximum efficiency, highest possible availability and cost-effectiveness are Powerline hallmarks. Powerline is an all-in-one conveyor system comprising mechatronic components and control elements, and is available with roller conveyors or chain conveyors. Powerline covers all logistical functions from conveying, transferring and diverting, to zero pressure accumulation.
Powerful and versatile
Powerline is designed for a wide range of applications in order fulfilment and distribution centres.
| Load carriers | Pallets (EUR-pallet, Chep, plastic, etc.) |
| Weight of transport object | Up to 1,300 kg |
| Performance | Up to 240 pallets per hour |
The individual types of Powerline components are available in different nominal widths and roller pitches.
Scalable modular design
Powerline is modular in design and uses the principle of common parts, meaning it can be adapted precisely in terms of size and investment. Powerline combines efficiency and flexibility: using intelligent motors and a new pneumatic accumulation system, every location can be switched on and off individually. Combined with a smart control system, an accumulation line can be established with a single drive unit. The integrated EcoMode allows Powerline to fulfil even the strictest demands for energy efficiency.
Using modern electrical and control concepts, with KiSoft SCADA a full visualization of Powerline is possible down to the level of the sensors and actuators. KiSoft SCADA is therefore the ideal complement to Powerline and supports plannable, proactive maintenance that is appropriate to the level that the conveyor system is used. Powerline is perfectly integrated into the KNAPP conveyor system product line and can be easily combined with other systems, such as the Open Shuttles or the Streamline conveyor systems.
Advantages of Powerline
- Intelligent control concept: proven AS-i bus system
- Full visualization: with KiSoft SCADA up to sensor and actuator level
- Scalable: precise adaptation in size and investment thanks to its modular design
- Powerful and versatile: conveys various types of pallets (EUR-pallet, Chep, plastic, etc.)
- Process innovation: fast installation and startup using the modular system and a maximum degree of pre-assembly
- Energy efficient: maximum availability and performance with minimum energy consumption thanks to the revolutionary accumulation stop concept. The drive unit uses soft-start function; speed controlled through NFC; integrated EcoMode.
- Easy maintenance: stream-lined spare parts management thanks to parts commonality; plannable maintenance with complete visualization provided by KiSoft SCADA
- Cost effectiveness: direct integration of work stations without separate drive units
Scandinavian KNAPP AB is a specialist in pallet conveyor system solutions. Find out more about KNAPP AB and pallet conveyor systems.
Green light for innovation
Open Shuttles are automated guided vehicles (AGVs) that can move completely freely across available spaces without any guiding lines. The intelligent Open Shuttles are ideally suited for complex conveying jobs within a warehouse. Rising demands for speed, flexibility and quality as well as increasing article numbers require new approaches to conveying goods within the warehouse. Furthermore, transport systems must be designed to be space-effective and flexible to quickly and economically respond to changing conditions. This is a task that pushes classic conveyors to their limits. KNAPP’s Open Shuttles are the ideal solution. The flexible Open Shuttles support numerous processes in the warehouse, combining flexibility, economy, safety, efficiency and scalability.
Flexible alternative to classic conveyor systems
The flexible Open Shuttles are suitable for various logistical applications in order fulfilment and distribution centres as well as in production. Open Shuttles provide an alternative to pallet or container conveyor systems and can be used in all warehouse areas. There are Open Shuttle variants for containers, trays and cartons or for pallets, depending on the logistical requirements. A special portable shelf allows the Open Shuttle to convey several load carriers at the same time.
The free-moving Open Shuttles handle the following tasks:
- Conveying: linking warehouse areas; express orders, etc.
- Supplying: goods-to-person work stations (e.g. zone picking)
- Picking: supporting manual picking (e.g. Pick and Go picking)
- Sequencing: establishing an exact sequence of load carriers on the move
- Tugger train: conveyance of several load carriers following the tugger train concept
| Load carriers | Containers, cartons, trays, pallets; optional: small portable rack to convey several load carriers (containers, trays or cartons) |
| Weight of transport object | Up to 100 kg (container, tray, carton) Up to 1,000 kg (small portable rack) Up to 1,300 kg (pallet) |
Maximum flexibility – complete safety
The Open Shuttles move about completely independently across free surfaces using innovative navigation technology, needing no inductive loops or track rails. Using laser navigation and sophisticated sensor technology, the Open Shuttles sense their way through their environment. By naturally scanning contours in this way they know exactly where they are at all times. The Open Shuttles respond dynamically to their environment, avoid obstacles, and independently plan their path through the warehouse as well as alternative routes. The Open Shuttles provide maximum safety for people as well as maximum flexibility, so they can also be used in highly frequented warehouse areas.
The KNAPP Fleet Management System manages and monitors the Open Shuttles centrally; new routes or procedures can be specified within a few short minutes. Thanks to their individual and swarm intelligence, the Open Shuttles are always there where the work is. They can communicate with each other and distribute the tasks among themselves independently. The Open Shuttles communicate with their environment using a speech module; the warehouse becomes a high-tech workplace where man and machine work hand in hand.
Advantages of the Open Shuttles
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- Easy integration: integration in an existing system without any structural modifications
- Fast ROI: low investment costs
- Space-saving: low space requirements with minimal use of static conveyors
- Flexibility: connect all warehouse areas; cover complex conveying distances
- Free navigation: constantly calculate the best route
- Safety: automatically avoid people and objects; safe interaction between people and machines thanks to a speech module
- Scalable: allows precise adaptation to the work requirements
- Expandable: easily expanded; new routes planned within minutes
- Energy efficient: autonomous energy management
- Low maintenance: low maintenance and servicing costs
- Communication: support all Host systems
The KNAPP subsidiary KNAPP Industry Solutions is the specialist in Open Shuttle solutions.
The overhead conveyor system is designed to convey goods on hangers. The overhead conveyor system is ideally suited for use in the fashion and textile industries as well as for retail applications, in production and in the automotive sector.
The following variants of the overhead conveyor system are available:
- Roll adapters with RFID technology
- Sorter Pocket with RFID technology
- Trolley systems
- Trolley-less systems
KNAPP subsidiary Dürkopp Fördertechnik is a specialist in overhead conveyor system solutions. Find out more about Dürkopp Fördertechnik and overhead conveyor system solutions.
Pucks are reliably transported by the puck conveyor system. Pucks are special holders in which objects are conveyed while held in a specific orientation. For example, lipsticks are held upright, individual contact lenses and special bottles are transported securely. The puck conveyor system is part of the KNAPP Medication Dispenser (KMeD) and is therefore an important component of MOCF solutions. The puck conveyor system supplies the KMeD with special vials and handles their onward conveyance.
KNAPP Logistics Automation in the USA is a specialist in puck conveyor systems.
Smart automation for dispatch
The OSR Shuttle™ Sorter is part of the OSR Shuttle™ product series and is based on proven shuttle technology. The OSR Shuttle™ Sorter efficiently automates and organizes the dispatch area and handles the sorting, buffering and sequencing of shipments. As a result, the OSR Shuttle™ Sorter fits right into KNAPP’s all-in-shuttle concept. The OSR Shuttle™ Sorter is ideally suited for omni-channel and multi-channel applications.
Flexible and scalable
The OSR Shuttle™ Sorter is characterized by its flexible and scalable design. The system is adjusted to individual warehouse requirements and can be easily expanded as needed. With the specialized control software KiSoft SRC, changes in the processes such as new business models can be easily made.
Ideal for high-performance applications
The OSR Shuttle™ Sorter is designed for use in order fulfilment and distribution centres, above all, in high-performance operations. The OSR Shuttle™ Sorter can process both containers and cartons. Using the OSR Shuttle™ Sorter, picking and dispatch processes are separated from each other. This allows resources to be used effectively and more flexibly, and evens out peak and slack periods.
The OSR Shuttle™ Sorter is ideally suited for the following applications:
- Supplying flow racks automatically and at the right time
- Buffering, sequencing and sorting goods that are ready for shipping
- Cross-docking
- Omni-channel and multi-channel applications
Advantages of the OSR Shuttle™ Sorter
- Automated and flexible dispatch and replenishment processes
- Sorting, buffering and sequencing handled by one system
- Handles both containers and cartons
- Flexible, scalable, reliable: modular system architecture based on proven shuttle technology
- Best use of resources by decoupling picking, replenishment and shipping
- Zero-error strategy applied to the replenishment process
- Minimal energy needed for maximum performance
The pocket sorter system is an overhead sorting and sequencing system that can be equipped with adapters for Sorter Pockets and/or with adapters for hangers. Both hanging and flat-packed goods are conveyed, sorted and sequenced in one system. RFID technology and handling single items separates the processing of goods from the sales channel.
The distinctive feature of the pocket sorter system is its unique sorting algorithm: matrix sortation. Matrix sortation puts parts that were batch-picked in various warehouse zones into a precise sequence and brings hanging and flat-packed goods together at a single pack station.
The pocket sorter system is ideal for fashion and retail as well as e-commerce and omni-channel applications. The pocket sorter system is therefore an integral part of the innovative goods-to-person picking solutions.
The pocket sorter system is a product of the KNAPP subsidiary Dürkopp Fördertechnik. Learn more about Dürkopp Fördertechnik.
The Split Tray Sorter is a high-performance sorting system that reliably and quickly sorts flat-packed goods.
The Split Tray Sorter is a high-performance sorting system that reliably and quickly sorts flat-packed goods. The Split Tray Sorter is above all suited for use in the fashion and textile sectors.
The Split Tray Sorter is a product of the KNAPP subsidiary Dürkopp Fördertechnik. Find out more about Dürkopp Fördertechnik and the Split Tray Sorter.