How your conveyor layout is the key to 99% order accuracy

The hidden cost of “walking” orders

When delivery performance drops, attention often turns to the final carrier. However, many fulfilment issues originate within the warehouse itself.

If staff are spending more time walking between racking and packing stations than picking items, the layout is likely the primary constraint. In many manual operations, walking alone can account for up to 50% of total picking time, making it one of the largest hidden inefficiencies within the warehouse.

These inefficiencies are not always obvious in day-to-day operations, but they become more pronounced as order volumes increase or during peak periods. Small delays at each step accumulate, leading to slower fulfilment, higher labour costs, and increased risk of errors.

A conveyor system should be considered as part of a broader movement strategy rather than a standalone piece of equipment. By introducing modular belt or roller conveyors, operations can establish a more structured and consistent flow. This allows teams to remain within defined zones, focusing on accuracy while the system manages transport between stages.

Automation through intelligent movement

Automation is most effective when it supports existing teams by removing repetitive, low-value tasks. Activities such as carrying completed orders to dispatch, transferring goods between zones, or moving items across longer distances can be handled more efficiently through conveyor integration.

This approach simplifies day-to-day operations without adding unnecessary complexity. It reduces physical strain on staff while improving consistency in how goods move through the warehouse.

In many cases, incremental improvements – such as linking two key areas or introducing accumulation zones – can deliver measurable gains without requiring a fully automated facility.

The logic of ZPA with DynoDrive

For more advanced fulfilment environments, the DynoDrive and DynoDrive One series offer a high level of control through Zero Pressure Accumulation (ZPA).

In a ZPA system, the conveyor is divided into zones that operate independently while communicating with each other. When a product reaches the end of the line or a downstream process slows, upstream zones pause automatically to prevent pressure building between items.

This “run-on-demand” approach provides several operational benefits:

• Reduced wear and tear: Motors operate only when required, extending system lifespan.
• Energy efficiency: Power consumption is lower compared to continuous-run systems.
• Product protection: Items are spaced and handled without contact, reducing the risk of damage.
• Improved flow control: Products move in a controlled sequence, supporting downstream processes such as packing and scanning.

Handling varied inventory with Tranzbelt

In fulfilment environments managing a wide range of products – particularly smaller items, polybags or irregular packaging – a belt conveyor such as the Tranzbelt S20 can provide greater stability.

The continuous belt surface supports consistent movement across longer distances and through elevation changes, ensuring items remain properly aligned throughout the process. This is particularly important in operations where product mix changes frequently or where packaging types are not uniform.

By maintaining a stable flow, belt conveyors help reduce interruptions and minimise the need for manual intervention, especially in areas where rollers may not provide sufficient support.

Removing the “kinks in the hose”

Most operations have specific points where flow becomes restricted. These may include transitions between levels, packing areas, or loading zones.

Identifying and addressing these constraints is key to improving overall throughput. In many cases, these friction points are accepted as part of the process, even though they have a measurable impact on efficiency.

For example, telescopic conveyors can assist with loading and unloading by extending directly into containers or trucks. While operator input is still required, they significantly reduce repeated manual handling and unnecessary movement. This not only improves turnaround times but also contributes to a more consistent and safer working environment.

Accuracy through technology

Barcode scanning is a proven method for improving order accuracy. However, its effectiveness depends on the consistency of product flow.

In manual environments, picking accuracy typically ranges between 96–99%. While this may appear high, even small error rates can become significant as order volumes increase.

When items arrive irregularly, in bulk, or out of sequence, scanning processes can slow down and become more prone to error. A conveyor system introduces a controlled flow, ensuring each item passes designated scan points in a predictable manner.

This level of consistency supports more reliable data capture, reduces the likelihood of missed scans, and helps maintain accuracy standards even during high-volume periods.

Building a more reliable fulfilment flow

Effective fulfilment relies on reducing unnecessary manual handling and creating a consistent, predictable movement of goods.

If staff are regularly lifting, carrying, or walking products across the warehouse, there is an opportunity to improve both efficiency and accuracy. Addressing these challenges does not always require large-scale automation, but it does require a clear understanding of how goods move through the operation.

Whether through a DynoDrive system, a Tranzbelt solution, or targeted improvements such as telescopic conveyors, the objective remains the same: to establish a reliable flow that supports both operational performance and customer expectations.

Contact us today to discuss your specific requirements or to arrange a free on-site visit.

enquiry@dyno.co.nz | 0800 144 044