In high-volume distribution centers, the return lane is often an afterthought… until it becomes a bottleneck. Empty totes need to be cleared, stacked, and sent back into rotation quickly to keep fulfillment moving. But when your vertical transport relies on legacy equipment, a simple return lane can turn into a noisy, high-maintenance headache.
Recently, Ryson teamed up with our long-term integrator partner, FORTNA, to solve this exact issue for one of the largest retailers in North America.
Replacing The Outdated Gravity Skate Wheel Spiral
The facility was struggling with an outdated gravity skate wheel spiral to move stacks of empty totes downward. While gravity-fed systems seem simple in theory, they present distinct real-world challenges in modern distribution centers:
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Product Damage: Stacked totes descending via gravity can accelerate unpredictably, leading to hard impacts, misalignments, and structural damage.
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Excessive Noise: The constant, uncontrolled rattling of plastic totes over metal skate wheels creates an incredibly loud working environment.
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Constant Monitoring: Staff frequently have to clear jams or adjust stuck stacks, taking time away from high-value tasks.
FORTNA recognized that true operational efficiency requires controlled, reliable movement. Together, we replaced the aging gravity system with a Ryson Powered Spiral Conveyor (Model 1700-600).
Why the Ryson 1700-600?
By upgrading to a powered vertical solution, the retailer achieved immediate improvements across three core areas:
1. Maintaining Tote Quality:
The proprietary slat belt design of the Ryson spiral ensures that stacked totes are handled gently. Because the movement is powered and entirely controlled from infeed to discharge, there is zero risk of totes colliding or accelerating out of control, drastically extending the lifespan of their fleet.
2. Low-Noise Operations:
Unlike the loud, metallic rumble of a gravity skate wheel system, Ryson spirals operate at an exceptionally low noise level, contributing to a safer and more comfortable environment for warehouse personnel.
3. Maintenance-Friendly Reliability:
Built for 24/7 continuous duty, our spirals feature heavy-duty components and sealed bearings, dramatically reducing the preventative maintenance schedule and eliminating the unpredictable downtime of the legacy slope.
Sustainability and Modernization
This successful integration is the first of many upcoming projects performing the same upgrade across this retailer’s network. It serves as a blueprint for their corporate modernization and sustainability initiatives: reducing waste from damaged totes, minimizing energy draw via efficient single-motor operation, and optimizing existing floor space.
A huge thank you to the team at FORTNA for their collaborative engineering and flawless integration. We look forward to modernizing the next facility together!