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Würth automates warehouse dispatch with ZPA powered roller conveyors

Würth New Zealand, a leading supplier of fixings, fastenings and chemicals to automotive, construction and engineering industries, faced a significant challenge when moving into their new Christchurch facility. With a larger building footprint and higher-capacity racking than ever before, their traditional manual conveyor systems simply wouldn't cut it. Looking for a partner who could deliver a modern, efficient solution, Würth turned to Dyno Conveyors - a company they'd successfully worked with before.

THE CHALLENGE

Outgrowing manual systems in a bigger, more demanding facility

After nine months of building their new Christchurch warehouse, Würth New Zealand knew their old way of working wouldn’t translate. The new facility was significantly larger, with racking systems that dwarfed what they’d used previously. “In our previous building, we had a lot of manual conveyors which were not particularly suited for efficient management of dispatch,” said Alex Chubb, who oversees warehouse operations, health and safety at Würth’s Christchurch branch. “And considering the capacity that we wish to grow to, we needed something a lot more suited for the situation that we’re moving into.”

The distances staff needed to cover were substantial, and manual handling at that scale simply wasn’t sustainable. If Würth wanted to meet their growth ambitions without exhausting their team, they needed a smarter system – one that removed unnecessary physical strain and kept pace with modern dispatch demands.

The Solution

24V DC MDR powered roller conveyors with intelligent ZPA technology

Dyno weren’t a new name to Würth. We’d previously installed a system at their Auckland warehouse that had delivered real results. So when it came time to kit out the new Christchurch facility, they came back to us. “We’d used Dyno in our previous warehouse in Auckland and that system worked for us and has given us a lot of success,” Alex explained.

This time, we designed and installed six lines of powered roller conveyor systems featuring advanced 24V DC MDR (Motor Driven Roller) technology with Zero Pressure Accumulation (ZPA). With 168 powered rollers across the installation, the system transformed how Würth’s dispatch team works.

Key components of our solution included:

  • DynoDrive 24V DC MDR Technology

The heart of the system lies in its DynoDrive motor driven rollers – where rollers contains their own internal motor built directly into the roller tube. Running on just 24 volts, it’s energy-efficient and significantly safer than traditional systems. “These new roller conveyors are powered, which make life a lot easier for us,” said Alex. “Given that they’re a low powered operation means it’s better for the environment. But also in the safety aspect, there’s a lot less risks if anything were to go wrong.”

  • Zero Pressure Accumulation (ZPA)

The ZPA feature ensures products don’t crash into each other. Orders move through about 80 cm zones, with loads stopping just before touching the product ahead. Once a dispatcher completes checking and pushes an order through, it automatically moves to the next zone. “If I place an order on one end of the conveyor, it will follow its way through until it meets an obstruction,” Alex described. “Once they’ve completed the task, they can push it through and then it will catch the next laser, which then brings it down to the packer seamlessly.”

  • Intelligent, compartmentalised movement

Laser sensors guide orders through the system, controlling flow along each 21.6-metre line. The system only runs when and where needed – reducing wear, noise, and energy consumption.

  • Designed to remove physical strain

The powered rollers – with Ø50mm galvanised steel construction on 64mm pitch – handle loads up to 25kg effortlessly. Staff no longer push heavy totes across long distances as the conveyors do the work for them.

  • Built for reliability and easy maintenance

The system’s modular design and proven MDR technology means lower lifetime costs and straightforward maintenance. “These new roller conveyors are great. The laser system, the compartmentalised movement, all in all it’s just made life a lot easier, a lot more efficient,” Alex noted.

  • A system fit for purpose

We took the time to understand Würth’s workflow and challenges, delivering a fit-for-purpose solution tailored to their exact requirements. “It has really solved a lot of the problems that I think we’d initially thought of,” Alex said. “They’ve made it really suit our operation perfectly.” And as no detail is too small, we even colour-match the conveyor lines to Würth branding.

The Result

A confident step into automation – and a more efficient dispatch operation

Initially, there was some hesitation. Adding technology can be daunting, especially when it means changing long-established workflows. But once the team found their rhythm with the new system, those concerns melted away. “The system is quite impressive,” Alex said. “We had some apprehension about moving into an automated system and generally adding technology doesn’t always make people feel comfortable, but now that we’ve gotten into it and we’ve found our feet with it, it has been fantastic.”

Perhaps most importantly, Würth has found a partner they trust. “I would recommend Dyno,” Alex concluded. “They’ve been great to work with. The products have always worked really well for us and it’s been great dealing with them. We’d certainly use them again in another project.”

Here’s what’s changed:

  • Staff downtime has dropped significantly, allowing the team to focus more on quality control and customer service rather than physical labour.

  • Dispatch efficiency has improved markedly, with orders flowing smoothly from picking to packing without bottlenecks.

  • Physical strain on staff has been eliminated, creating a safer, more sustainable work environment.

  • Energy consumption is minimal, thanks to the 24-volt powered MDR system that’s both cost-effective and environmentally friendly.

  • The operation is future-ready, with a system designed to scale alongside Würth’s growth ambitions.

  • Maintenance is straightforward, with the system’s proven technology and our bi-annual preventative maintenance program ensuring optimal performance.

Customer Testimonial

The Dyno system has really solved a lot of our problems

“We had some apprehension about moving into an automated system, but now that we’ve gotten into it and found our feet with it, it has been fantastic. It has really solved a lot of the problems that I think we’d initially thought of – they’ve made it really suit our operation perfectly.”

Alex Chubb

Würth New Zealand

Products

Dyno products used in this project

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