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.
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.

Affordable Automation Solutions That Boost Labor Productivity

Making Warehouse Automation Affordable & Productive

Many manual warehousing, distribution and fulfillment operations hesitate to invest in automation to help address their labor challenges, assuming that the expense will put these solutions beyond their reach. But that assumption doesn’t apply to every system within the automation spectrum. In fact, there are a few well-proven, affordable automated solutions available in the market that quickly deliver an increase in labor productivity and efficiency, thereby significantly shortening their return on investment (ROI) period.


Before we explore those options, let’s first review some of the signs that it’s time to transition at least part of a manual operation into an automated solution:

3 Reasons Warehouse Operations Should Be Automated

  • A shortage of available labor. With the pre-COVID-19 unemployment rates hovering around 2-3 percent nationally, it has been difficult to attract and retain warehouse employees. Many facilities also struggle with high absenteeism rates among their workforce, leading to throughput inconsistencies. The associated costs of recruiting, hiring and training workers who ultimately don’t pan out can be as much as 150% of their salary.
  • An increase in overtime. With fewer available workers (and employees who don’t consistently show up), the associates who are onsite are often asked to work additional hours at higher wages in order to keep up with the work.
  • Missed shipping deadlines. Without adequate staffing, it’s challenging to meet customers’ service level agreements (SLAs). Not receiving their order on time can not only anger them, a recent survey found that as a result of poor customer service, 37% would change suppliers; 28% would post a negative online review; and 26% would complain via social media.
  • The addition of another shift. To avoid overtime and prevent missed shipping deadlines, many operations add a second (or third) shift, doubling or tripling their labor costs.


If your manual warehousing operation is experiencing these labor-related issues, then it’s time to consider a foray into affordable automation. There are three automated solutions that fall on the lower end of the expense spectrum that directly address these labor challenges: Motorized transport conveyor systems, Warehouse Design incorporating light-directed putwalls, and simple sortation systems.


A Modern Conveyor Design used to improve Material Handling Systems within Hi-Tech Warehouse Operations


3 Warehouse Automation Systems That Will Not Break The Bank


Motorized Transport Conveyor Systems


Simple, motor-driven roller (MDR) transport conveyor that moves items from point A to point B eliminates worker travel time as they move through a facility performing various tasks. Research has found that workers spend up to 70% of their time walking around, transporting goods from receiving to storage, walking up and down aisles to pick products, pushing carts from picking to packing, and so on. By assigning them to specific areas (or zones) within a facility where they pick required items then place them on a conveyor to carry the items off to packing automatically cuts worker travel time significantly. Instead of walking, associates spend more time on picking, making them more productive. Additionally, MDR conveyor powers specific sections of the equipment as needed, reducing energy consumption, minimizing wear and associated downtime for maintenance and repair, and running at low noise levels. All of these benefits further contribute to cost savings calculations.


Warehouse Design Incorporating Light-Directed Putwalls


Equipped with small modules that illuminate with a combination of lights, numbers, and arrows, putwalls are a series of divided shelves. Each opening typically represents a unique order; when an operator scans the barcode of an item, all the modules mounted above the cubby positions whose orders that require that item light up to direct the placement and quantity of that pick. Often implemented in conjunction with transport conveyor, putwalls allow an operation to utilize different picking strategies such as wave picking, where multiples of the same item required for several orders are picked simultaneously, then separated into discrete orders. With a light-directed putwall, a single operator can fill as many as 20 orders at one time while remaining in one area, saving time. With the light modules, an associate no longer has to read packing lists to match picks to orders, also bolstering productivity. Putwalls are often mounted on casters, allowing them to be easily added or removed from a packing zone as needed.


Warehouse Operations with Simple Sortation Systems


Ideal for sorting anything from 1,000 to 8,000 units per hour, simple sorters such as push-tray (with integrated bars that push a load off to the side) or bomb-bay (with a base that splits in the middle and swings open to drop the load down) styles can also be among the most cost-effective for warehouse operations. Both sorters readily accommodate products in a variety of dimensions, shapes and weights; both can be easily expanded into additional areas within a facility as an operation’s needs change. Utilizing one of these systems within your material handling solutions can dramatically improve productivity by automatically sorting items into discrete orders, allowing workers who previously sorted these items by hand to be reallocated to other tasks.


We’d love to talk with you about applying one or more of these affordable automation solutions to your operation to increase your workforce’s productivity. Want to learn more about how DCS can help your operation? Connect with us.



Satyen Pathak, Account Executive,

As an SME in material handling, Satyen has an extensive background in creating solutions for the retail/e-comm, Parcel, Post, and baggage handling market verticals. He has worn several hats including Product Management, Applications Engineer, Technical support and most recently as an Account Executive with DCS. Satyen has conducted numerous educational speaking engagements and has sat on committees for MHI providing directional insight for the industry.