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THE PROBLEM
The client needed to install and commission new conveyor systems to integrate multiple Autobaggers into an active fulfillment center without interrupting operations.
The brownfield retrofit required close coordination across mechanical, electrical, and controls teams, with multiple equipment deliveries and staged cutovers.
Execution was further constrained by limited design flexibility, active operations, and required field adjustments.
KEY QUESTIONS
- How can new conveyor systems be installed and commissioned in a live fulfillment center without interrupting operations?
- How can multiple Autobaggers be integrated while sequencing mechanical, electrical, and controls work efficiently?
- How can future equipment be enabled during the initial installation to reduce downstream disruption?
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THE SOLUTION
Maveneer executed a direct-to-implementation delivery approach, focusing on constructability, sequencing, and coordination rather than system redesign. The project was planned and executed to allow mechanical installation to progress up to tie-in points while operations continued, with electrical and controls work staged closely behind.
Targeted field-driven adjustments were made within existing client design standards and constraints. Commissioning and cutover were performed in defined phases aligned with Autobagger availability, and infrastructure for a future Autobagger was installed and tested in advance to minimize disruption during a later integration.
KEY RESULTS & INSIGHTS
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Successfully installed and commissioned over 500 feet of conveyor systems linking four new Autobaggers into the existing operation.
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Delivered throughput of 1,080 totes per hour per line in the current configuration.
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Significant improvement in labor efficiency, allowing labor to be allocated to higher-value tasks.
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Completed multiple staged cutovers with zero unplanned operational downtime.
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Enabled future Autobagger integration with minimal incremental effort.
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Updated the client’s existing controls library to enable repeatable deployment across other fulfillment centers in the portfolio.
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