This is a real story about a real plant. We are sharing it because the numbers speak better than any brochure.
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THE SITUATION — BEFORE
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Client: Consumer goods distribution company
Location: Ecotech-III, Greater Noida, Uttar Pradesh
Operation: 6, 000–8, 000 cartons per day dispatched from warehouse ground floor to loading bay at dock level (+1.2 metres)
The problem:
❌ 7 workers manually carrying cartons to dock — each trip 35 metres
❌ Average handling rate: 380 cartons per worker per shift
❌ Physical fatigue causing 3–4 workers per shift to underperform after lunch
❌ 3 workplace injuries in 12 months — two requiring medical leave
❌ Peak season temporary worker costs: ₹1.4 lakhs per month above base
❌ Dispatch completion frequently missed evening truck cut-off by 15–25 minutes
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THE NEO CONVEYORS SOLUTION
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After a half-day site survey and layout study, our engineering team proposed a 3-section integrated system:
Section 1 — Ground floor accumulation:
• 20m × 600mm powered roller conveyor from pick & pack stations to incline feed point
• Variable speed (0.4–1.0 m/s) to match pick rate
Section 2 — Inclined transport:
• 6m inclined cleated belt conveyor rising 1.2m to dock level
• 18° incline, 600mm width, anti-slip cleated PVC belt
• Load capacity: 800 kg distributed
Section 3 — Dock-level distribution:
• 14m × 600mm powered roller line across dock face with 4 zone stops
• Manual divert gates at each truck bay position
Total: 40m of integrated conveyor — designed in 2 days, commissioned in 16 working days.
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THE RESULTS — AFTER
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✅ Manual dispatch workforce reduced from 7 to 2 (supervisor + dock-end operator)
✅ Throughput increased from 6, 000 to 9, 900 cartons/day — a 65% increase
✅ Physical strain injuries: zero in 20 months since commissioning
✅ Dispatch completion: evening truck cut-off met on 100% of working days since installation
✅ Peak season temporary worker requirement: eliminated entirely
✅ Monthly labour saving: ₹1.58 lakhs
✅ Full project ROI achieved: 11 months
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THE NUMBERS SUMMARY
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Project cost: ₹17.4 lakhs
Monthly saving: ₹1.58 lakhs (labour) + ₹0.3 lakhs (temp workers)
Annual saving: ₹22.56 lakhs
ROI timeline: 11 months
5-year net saving: ₹95 lakhs+ (against ₹17.4 lakh investment)
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