Anand Jolliz Conveyor System Case Study
From 9 to 18 Trucks a Day: Solveyor Automation Helps Anand Jolliz Improve Material Flow and Dispatch Capacity
Project Overview
Anand Jolliz expanded its manufacturing operations to meet increasing production requirements. With the expansion, production capacity increased significantly, but the higher output created a new operational challenge.
The production team was able to manufacture more products, but the existing warehouse and internal material movement process was struggling to handle the increased volume.
As product accumulation increased around the warehouse and dispatch areas, material handling became a bottleneck.
Solveyor Automation designed and implemented a customized conveyor and material handling system to improve the movement of finished products through the facility and support the increased production and dispatch requirements.
The project combined spiral roller conveyors, inclined conveyors, and roller conveyor sections to create a more organized material-flow route around the existing factory layout.
The result was a significant improvement in dispatch capacity, with daily truck movement increasing from 9 trucks to 18 trucks per day.
The Challenge
Production Had Increased, but Warehouse Handling Had Become a Bottleneck
The expansion helped Anand Jolliz increase its production capacity substantially.
However, higher production created additional pressure on the downstream operations.
More production meant more finished products had to be moved, handled, organized and prepared for dispatch.
The existing material-handling process was finding it difficult to keep pace with this increased volume.
The main challenge was therefore not simply production.
It was the flow of material after production.
Key Challenges Faced by Anand Jolliz
Higher production volume
The company’s expansion resulted in a substantial increase in production. The downstream material-handling system also needed to accommodate this additional output.
Warehouse bottleneck
As more products entered the warehouse and dispatch flow, internal movement became increasingly difficult to manage efficiently.
Increased manual handling
Higher product volumes required more movement between different areas of the facility, increasing dependence on manual material handling.
Dispatch pressure
The increased production could not be converted into higher dispatch capacity efficiently because warehouse and internal material movement had become a constraint.
Limited space for conventional conveyor routing
The factory layout required a customized conveyor arrangement capable of handling changes in direction and elevation without consuming excessive floor space.
The Solveyor Automation Solution
A Customized Conveyor System Designed Around the Existing Factory Layout
Solveyor Automation studied the material movement requirements and developed a customized conveyor solution based on the existing production and warehouse environment.
Instead of using a single conveyor configuration, the project combined different conveyor types to address different stages of the material-flow process.
The objective was to create a continuous and more organized route for moving products from the production area toward downstream handling and dispatch.
Spiral Roller Conveyor
A customized spiral roller conveyor was used to facilitate multi-level product movement.
The spiral configuration allowed products to move between different elevations while making better use of the available vertical space.
This was particularly useful for a facility where a conventional straight conveyor would require significantly more floor area.
Inclined Conveyor
An inclined conveyor system was incorporated to move products between different levels.
The inclined section provided a controlled conveying path and helped connect different areas within the facility.
Roller Conveyor
Roller conveyor sections were integrated into the overall material-flow system for product transportation through the required areas.
The roller sections provided a practical conveying solution for compatible packaged products and cartons.
Customized Conveyor Structure
The conveyor system was installed using a fabricated support structure designed around the existing factory conditions.
The supporting arrangement accommodated the conveyor route, elevation changes and available installation space.
How the System Improved Material Flow
The project was designed to connect the movement of products between production, warehouse handling and dispatch.
The resulting material-flow route can be represented as:
Production → Conveyor Transfer → Inclined Movement → Multi-Level Transfer → Warehouse Handling → Dispatch
This approach helped reduce unnecessary manual movement and created a more structured route for handling the increased production volume.
The conveyor system therefore addressed the gap between production capacity and downstream material-handling capacity.
Measurable Results
9 Trucks → 18 Trucks Per Day
One of the clearest measurable outcomes from the project was the increase in daily truck movement.
Before the improved material-flow system, the operation was handling approximately:
9 Trucks Per Day
After implementation:
18 Trucks Per Day
The calculation is:
(18 − 9) ÷ 9 × 100 = 100%
Therefore, daily dispatch capacity increased by approximately:
100%
This means the operation reached approximately 2X its earlier daily truck movement, handling around 9 additional trucks per day compared with the previous level.
This is the strongest quantitative result from the project because it can be directly calculated from the reported daily dispatch figures.
Approximately 40% Business Growth
The improved material-handling and dispatch capability supported the company’s expansion and higher production requirements.
The project was associated with approximately:
40% Business Growth
This figure should be understood as the reported business growth associated with the expansion and improved operational capacity, rather than claiming that the conveyor system alone generated 40% revenue growth.
The conveyor solution helped provide the material-flow capacity required to support the increased volume.
Approximately 10% Reduction in Manpower Requirement
The increased use of conveyor-assisted material movement reduced the requirement for repetitive manual transportation.
The project achieved an approximately:
10% Reduction in Manpower Requirement
This helped the operation handle a higher movement volume with less dependence on manual product transportation.
Before vs After
Area
Daily truck movement |
Dispatch capacity |
Daily truck handling |
Production expansion |
Warehouse movement |
Manual handling |
Manpower requirement |
Material flow |
Multi-level movement |
Before
9 trucks/day |
Baseline |
9 |
Created downstream pressure |
Bottleneck |
Higher dependence |
Baseline |
More dependent on manual movement |
Operational challenge |
After
18 trucks/day |
Approximately 100% higher |
18 |
Better supported by material flow |
More organized flow |
Reduced requirement |
Approximately 10% lower |
Conveyor-assisted |
Spiral and inclined conveying |
The Key Problem Solved by Conveyor Automation
The project demonstrates an important manufacturing challenge.
When production capacity increases, the rest of the operation has to keep pace.
Increasing production without improving internal material movement can simply move the bottleneck from the production line to the warehouse or dispatch area.
That is what Anand Jolliz was experiencing after its expansion.
The company had increased its production capability, but the higher output created pressure on warehouse handling and dispatch.
Solveyor Automation addressed this constraint through a customized conveyor and material handling system.
The solution helped create a better connection between:
Production → Material Movement → Warehouse → Dispatch
Business Impact
The project provided Anand Jolliz with a conveyor-assisted material-flow system designed around its actual operational requirements.
The key benefits included:
Higher Dispatch Capacity
Daily truck movement increased from 9 to 18 trucks per day, representing approximately a 100% increase.
Better Warehouse Throughput
The conveyor system helped move products more continuously toward downstream warehouse and dispatch operations.
Reduced Manual Handling
Automated conveying reduced the need for repetitive manual transportation.
Better Use of Factory Space
The spiral conveyor configuration enabled multi-level movement while using the available vertical space.
Support for Production Expansion
The improved material flow helped the downstream operation handle the higher volume generated by the company’s production expansion.
Lower Manpower Requirement
The project resulted in an approximately 10% reduction in manpower requirement for the relevant material-handling activities.
Why a Customized Conveyor System Was Required
A standard straight conveyor would not have addressed all of the requirements created by the factory layout.
The project required movement across different elevations and through available production and warehouse space.
The customized solution therefore combined:
- Spiral roller conveying
- Inclined conveying
- Roller conveying
- Fabricated structural supports
- Multi-level product movement
- Customized conveyor routing
This approach allowed the conveyor system to be designed around the facility instead of requiring the facility to be redesigned around a standard conveyor.
Conveyor Automation for Food and Namkeen Manufacturing
Food manufacturers often need to move products between production, packaging, storage and dispatch areas.
As production volumes increase, manual material handling can become a constraint on warehouse throughput and dispatch operations.
Customized conveyor systems can help manufacturers improve internal product movement by creating defined conveying routes between operational areas.
Applications can include:
- Namkeen manufacturing
- Snack food production
- Packaged food handling
- FMCG manufacturing
- Food packaging
- Finished goods movement
- Production-to-warehouse transfer
- Warehouse-to-dispatch movement
- Multi-level material handling
- Internal factory logistics
Project Highlights
9 → 18 Trucks/Day
Daily truck movement increased from 9 to 18 trucks.
100% Increase
The change from 9 to 18 trucks represents a 100% increase in daily dispatch capacity.
2X Daily Dispatch
The operation reached approximately twice its previous daily truck movement.
~40% Growth
Reported business growth associated with the company’s expansion and increased operational capacity.
~10% Manpower Reduction
Reduced manpower requirement for relevant manual material-handling activities.
Multi-Level Material Movement
Spiral and inclined conveyors enabled product movement across different elevations.
Customized Conveyor Layout
The system was developed around the customer’s factory layout and material-flow requirements.
A Conveyor System Designed for Growth
Anand Jolliz Namkeen’s challenge was created by growth itself.
The company’s expansion increased production, but higher production also increased the amount of material that needed to move through the warehouse and dispatch process.
Solveyor Automation’s role was to help close that operational gap.
By implementing a customized conveyor system, the company was able to improve internal material movement and increase its daily dispatch capacity from 9 trucks to 18 trucks.
The project shows why production expansion should be considered together with material handling, warehouse throughput and dispatch capacity.
Need to Handle Higher Production Without Creating a Warehouse Bottleneck?
If your production capacity has increased but your warehouse, internal material movement or dispatch process is struggling to keep pace, a conveyor-based material handling system may help.
Solveyor Automation designs customized conveyor systems, material handling solutions and end-of-line automation for manufacturing and packaging applications.
Our team can evaluate your production flow, available space, product movement requirements and dispatch process to develop a conveyor solution around your plant.
Talk to Solveyor Automation About Your Conveyor Requirement
Request a Conveyor Solution →
Project Information
Client: Anand Jolliz
Industry: Food & Namkeen Manufacturing
Project Type: Customized Conveyor Automation
Solution: Conveyor & Material Handling System
Primary Challenge: Warehouse and dispatch bottleneck after production expansion
Conveyor Types: Spiral Roller Conveyor, Inclined Conveyor, Roller Conveyor
Daily Truck Movement: 9 → 18 trucks/day
Dispatch Capacity Increase: Approximately 100%
Reported Business Growth: Approximately 40%
Reported Manpower Reduction: Approximately 10%
Application: Internal Material Movement, Warehouse Handling & Dispatch
Automation Partner: Solveyor Automation