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Package Handling
DCS’s design and engineering team has more than 40 years of experience creating unique parcel handling systems for diverse customer applications. With installations including semi-automated handling in small city distribution centers and fully automated, integrated hubs with advanced conveyor and sorter equipment, DCS routinely thinks outside the box.
E-Commerce and Multi-Channel Fulfillment
DCS designs and implements end-to-end warehouse automation solutions for e-commerce and multi-channel retailers that address numerous workflow challenges. This includes solutions for receiving, putaway, storage, replenishment, order fulfillment, picking, packing, sortation, and outbound shipping. Our custom integrated warehouse, distribution, and fulfillment systems draw from a deep pool of conventional, semi-automated, and automated material handling technologies.
Various Distribution Applications
Whether an operation is considering the construction of a new distribution or fulfillment center, or a retrofit or expansion of an existing facility, it’s important to create a solution that fits the overarching supply chain strategy. DCS has four decades of experience designing and integrating comprehensive, end-to-end material handling solutions that meet a multitude of operational goals. Whether conventional, semi-automated, or fully automated, DCS can help your organization implement a custom solution that meets its goals while maximizing return on investment (ROI).
Supply Chain Consulting
The DCS Supply Chain Consulting team offers a range of services to help your operations address the challenges it faces. Working in partnership with you, DCS consultants analyze your business data- existing workforce, workflow processes, inventory, order data, operations, and more- to determine a strategy that addresses your unique needs. Whether you need an operations assessment, process improvement recommendations, or distribution design services, DCS consultants will help guide you to the material handling system or operational solution that best meets your current and future needs, as well as your budget.
Customer Support
Keeping your warehouse operations and material handling systems running smoothly and at the peak of productivity are the goals of DCS’ Customer Service Team. By partnering with DCS, your warehouse automation solution is supported from commissioning to end of life. You’ll receive comprehensive in-house training of your personnel, including specialized training of your designated internal system expert. Plus, DCS offers a complete package of spare parts and expert system troubleshooting support from qualified engineers dedicated to your installation.
System Design & Integration
DCS offers a broad range of material handling equipment and automated system design, installation, and integration services for a multitude of projects. These include retrofits, expansions, upgrades, and more. While every project is unique, our system design and execution processes are the same, encompassing meticulous attention to detail, frequent communication, and a dedicated partnership with our clients.
About Us
Designed Conveyor Systems (DCS) has 40 years of experience serving major clients in multiple industries by providing material handling, full-scale warehouse operations, and conveyor design solutions that are custom crafted for their needs. DCS does not sell ready-made conveyor systems but builds relationships that empower collaboration to craft custom warehouse designs together. DCS utilizes consulting, engineering design, project management, installation services, and client support to ensure our customers can keep their promises to deliver on time.
Projects
With more than 40 years of experience providing automated system design, installation, and integration services, DCS has created solutions for companies throughout the United States in a broad range of industries and markets. We’ve completed more than 1500 projects ranging from greenfield facilities with completely new systems to expansions and retrofits of existing operations.
Upcoming Events
Designed Conveyor Systems values building strong relationships with our clients. Join us at our upcoming events to collaborate and discover how we can design a custom warehouse solution tailored to your unique needs.
CASE STUDY: Tour Graco’s Greenfield DC with Automated System from DCS
CASE STUDY: Tour Graco’s Greenfield DC with Automated System from DCS
Graco Inc., a global leader in fluid handling equipment, partnered with Designed Conveyor Systems (DCS) to outfit its new 500,000-square-foot greenfield Worldwide Distribution Center (DC) in Dayton, Minnesota with state-of-the-art, end-to-end automated systems. Completed on schedule in just 24 months, the facility went live in May 2024, and features cutting-edge automation from KNAPP, Geek+, and Brock Solutions.
Graco’s previous 227,000-square-foot distribution center was nearing capacity. Housing more than 40,000 SKUs, the leased facility faced constraints including an aging crane-based mini-load AS/RS and limited expansion options. Pick consolidation and pack-out processes had become bottlenecks, often requiring overtime.
To address growth projections and system limitations, Graco opted to build a new automated facility and selected DCS for its brand-agnostic, end-to-end approach. Take a tour of the operation via the video below.
Automated Order Fulfillment and Pick Consolidation
DCS collaborated with Graco’s operations team and automation suppliers to deliver a tailored solution. At the heart of the new system is the KNAPP OSR Shuttle Evo AS/RS, with 25 levels of shuttles and automated lifts feeding six goods-to-person picking stations.
Inventory not suited for the shuttle system is stored in pallet racks and carton flow zones with pick-to-light modules. To eliminate manual order consolidation, DCS implemented Geek+ PopPick directed by Brock Solutions’ warehouse control system (WCS). The system uses autonomous mobile robots (AMRs) to stage and deliver totes for sequencing and routing to a 12-station pack-out zone.
Pack stations are equipped with light-guided systems to highlight specific products or tote locations, boosting accuracy and ergonomics. The facility also includes 1.5 miles of motor driven roller conveyor, all coordinated by Brock’s WCS interfacing with Graco’s warehouse management system (WMS).
The Results
The project met its timeline thanks to DCS’s comprehensive project management, close coordination with contractors, and early associate training.
“DCS truly was an end-to-end automation project manager,” said Jeff Weber, Graco’s Distribution Operations Manager. “The DCS team made sure all the equipment was here on time and coordinated all of our automation vendors — all the way from commissioning, to install, to startup. They have been very helpful and supportive through this entire project.”
Thinking about implementing automation in a new or existing distribution center? Connect with DCS to learn how we can help you achieve your goals.