Integrated By: Babush Material Handling Systems, Sussex, WI
Throughput Jumps with
New Conveyors
 A Company on the Move
BuySeasons is a fast growing online costume retailer with over 10,000 items available to choose from. When they decided a jump in productivity was desperately needed, they looked to Babush Material Handling Systems to install a conveyor system that would provide them with the ability to handle seasonal increases in orders that are consistent in their industry. The main objective was to reduce the time from order picking to shipping to insure delivery of costumes in the timeliestmanner. With three main seasons - Halloween, Christmas, and Easter, it was imperative that the system had the ability to handle the peck loads that occur as the special dates gets closer.
"This operation is helping BuySeasons meet its strict service commitment to customers. We are extremely impressed with the expertise Babush offered; they were able to take our vision and goals and turn them into reality."
--President and CEO Jalem Getz
How the system works:
The order pickers take carts along rows of racks and pull items to fill each individual order. These carts are then taken to 20 packing stations where packers place  the items and the packing slip in boxes that best suit the size of the order. The filled boxes are placed onto the live roller accumulation conveyor running in front of each packing station. The boxes then travel to a Live Roller Zero Pressure Accumulation Conveyor which controls the boxes before they enter the divert area before the shipping stations. Through the use of a Double Powered Pivot Diverter they are able to function with maximum efficiency based on their order volume. BuySeasons can run one lane in the shipping area when volume levels are low, requiring only one shipper to handle the load. As the volume increases they are able to activate the diverter which allows them to divert boxes to two separate lanes and increase the amount of shipping personnel to four at peck volume levels. After the boxes have been scanned and the shipping label applied the boxes move down the conveyor to the box sealers. Here the boxes are automatically closed and taped, then travel to a merge area where two lanes converge and the boxes travel single file to the loading dock.
Benefits
The previous system was a basic roller coaster design utilizing gravity conveyors. This system was able to handle 8000 boxes over 3 shifts at peck volume. The new system has the ability to handle 20,000 boxes over a 2 shift period. Babush designed a system that provided BuySeasons a 100% increase in throughput with a 25%-35% increase in productivity; therefore requiring less labor during non-peck volume levels. An additional benefit was BuySeason’s ability to reduce costs related to packing errors resulting in less returned items.
System Hy-Lites
- Facility Size: 81,000 sq. ft. – 66,000 sq. ft. of distribution
- Employees: 55 full time employees, seasonal peck of 250 employees
- Product Handled: Online costume retailer
- Types of Conveyors: Minimum Pressure Accumulation Live Roller Conveyors, Live Roller Curve Conveyors, Zero Pressure Accumulation Live Roller Conveyors, Live Roller Spur Conveyor, Double Powered Pivot Diverter, Flexible Roller Conveyor
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