Brookvale International implemented Hytrol conveying systems throughout their facility to increase productivity and meet shipping windows.

The operation at Brookvale centers completely around the receiving, storing, order processing, and shipping of all apparel for PUMA. PUMA is the global sportlifestyle company known for fusing the influences of sport, lifestyle and fashion. PUMA’s unique industry perspective delivers the unexpected in sportlifestyle footwear, apparel and accessories, through technical innovation and revolutionary design. Brookvale works in partnership with PUMA North America to distribute PUMA apparel through the United States and Puerto Rico from their Carson, California distribution center.

Image courtesy of Hytrol

Brookvale’s biggest concern is to meet their maximum number of cartons per day, which is more complex than simply pushing product through. The adjustable speed of the systems was a requirement, as well as the ability to move cartons through the only necessary areas before shipping.

Upon receiving items, the conveyor system transports boxes of apparel in totes into a pick module (replenishment) where the apparel is stored in specific locations for picking. The conveyor system also transports empty totes to the pick module where apparel is picked and placed into the totes. Totes are then moved either to the VAS (Value Added Service) area, packing, a “hospital” and “no read” line where errors are corrected, or are recirculated through the pick module. After arriving at the packing area, the totes are manually removed from the conveyor and the contents packed into shipping cartons.

The packed shipping cartons are manually placed onto a take away conveyor and moved across an inline scale to either a UPS shipping conveyor or a consolidation loop. The remaining empty totes in packing are also manually placed onto the same take away conveyor where they move toward the inline scale. They are automatically diverted by a pop-up transfer onto the empty tote line.

Image courtesy of Hytrol

The system was designed to enable Brookvale to change the speed of the equipment to accommodate throughput. Adjustments were made after installation to keep pace with customer needs. Currently, the system handles between 20 and 25 thousand pieces a shift, with a goal of 40 thousand.

In addition to basic receiving, stocking, picking, and shipping, the Brookvale center also has the capability of handling value-added services such as “hang-tags,” custom bagging, pricing, and other customer requirements. Hytrol conveyors are also used to help with these services. Throughout the facility, Brookvale utilizes Hytrol Belt, Roller, Slider Bed, Roller Bed, Zero-pressure Accumulation, Trash Belt, Pop-up V-belt Transfers, and Gravity Conveyors.

"Everything is working fine. We've had no problems. The conveyor system does exactly what we want it to do. We have a max that we have to meet every day and it's met that. The installation went good. The Hytrol Project Manager was on-site when he was needed." 

- Gary Wicks: General Manager, Brookvale International