IntelliTrak…the definitive solution for a wide variety of material handling challenges:

Every day, IntelliTrak engineers are challenged with developing innovative, custom-designed conveyor systems to help customers with their specific material handling issues. Whether it’s how to move a long and/or heavy agricultural part efficiently or the need to increase throughput in a smaller footprint, IntelliTrak has the solution.

Don’t just take our word for it. Take a look at what we’ve done for our customers faced with some of those same challenges:

Space-saving shuttle makes large part transfer easy.

Opportunity:
Manufacturer of agricultural attachments needed a finishing system complete with washers and ovens that would accommodate oscillating parts with varying speeds and include forward/reverse capabilities.
Solution:
Because max load was under 3,000 lbs., the IntelliTrak 1500 Series, with shuttles on each end, proved to be the best solution for easiest part transfer in the smallest amount of space. Customized controls provided the ability to program part-specific recipes.
IntelliTrak 1500 Series Heavy Industrial Finishing Overhead Conveyor with Shuttle

IntelliTrak provides aerospace manufacturer a creative solution for moving a very long part in a small space.

Opportunity:
Manufacturer of aerospace components needed finishing conveyor system for long composite plane part. With limited space for new construction and multiple lanes and lifts required for throughput, a standard conveyor system just wouldn’t work.
Solution:
IntelliTrak designed, manufactured and installed the 1500 Series overhead conveyor with a 36’6” load bar and a double trolley carrier. To efficiently move the over-sized load bar in the narrow floor space, IntelliTrak installed 3 shuttle assemblies that fed into 20 shuttle stop assemblies and an empty carrier return lane (saving floor space and construction costs).  The added functionality of the forward/reverse ability of the IntelliTrak system improved the overall process. And the solution for lifting a 36’ load bar? A custom-designed double split-cantilever lift with a single drive shaft. Problem solved.
IntelliTrak 1500 Series Airplane Wing Finishing Overhead Conveyor with Shuttle

Removed old system; Installed new, modular IntelliTrak Overhead Conveyor System—all in three weeks!

Opportunity:
Large manufacturer of construction equipment needed a 40-year-old chain conveyor removed and a new overhead conveyor installed in three weeks!
Solution:
IntelliTrak designed, manufactured and installed a 3500 Series Overhead Conveyor with 2600 ft. of conveyor, 40 carriers (10,000 lb. capacity), two vertical lifts and finishing system components. IN THREE WEEKS! HOW? Only possible due to the modularity of the IntelliTrak System, that not only shortens installation time, but allows for preliminary engineering and pre-assembly.Results:
First day after shutdown, system was up and running. By the end of the week, it exceeded the previous systems’ production levels, meeting TAKT time of 5 minutes per part; 100 parts per day. Increase production with the added bonus of a cleaner, quieter, safer, more pleasant work environment!
IntelliTrak 3500 Series Heavy Industrial Finishing Overhead Conveyor

For one large manufacturer of construction equipment, IntelliTrak’s modular conveyor system is an industry game-changer.

Opportunity:
Large manufacturer of construction equipment needed a conveyor system for a new facility. They chose the IntelliTrak 3500 Series largely because of its promise of extreme modularity.
Solution:
IntelliTrak’s friction drive system (no chains) and modular support structure (bolted, not welded), is easily modified, expanded and moved—the entire system if required! As parts change and new models are developed or quantities changed, this system is able to easily move with those changes. Not only that, but the system’s forward/reverse capabilities and the use of spurs, all served to improve processes, reduce downtime and increase productivity. All components are standardized, so that moving forward, further installations and modifications will be simple with minimal project management required.
IntelliTrak 3500 Series Heavy Industrial Finishing Overhead Conveyor

Perfect example of IntelliTrak’s modularity: In one weekend, at the customer’s request, IntelliTrak added switches and a cooling lane, all while production continued, with no downtime and no overtime.

Repeat customer, Tier 1 Automotive supplier, adds new vehicle line, expands system and saves money, all without missing a beat.

Opportunity:
In 2006, IntelliTrak installed a system in the customer’s new building.
When they were awarded a new contract in 2015 for a new vehicle, they had a choice: purchase a new conveyor system or modify the existing one.
Solution:
The inherent flexibility of the IntelliTrak 500 Series Overhead Conveyor made the decision simple: MODIFY it!
Instead of having to build an entirely new system (as they would have had to do with a traditional power and free chain system), IntelliTrak was able to remove part of the old system, add new conveyor onto the old system, even reusing some of the existing system, and save the customer thousands of dollars in both equipment and downtime.
Scope of project:
Added 12 new stations with rotating motorized carriers equipped with RFID and powered conductor rail. The customer’s assembly requirements were complex, with a need for varying speeds and the following requirements:

  • 52 second TAKT time
  • 42 minute same day delivery
  • 90 second electrical test
  • Accumulation for 2 HLA stations
  • Indexing
  • Broadcast pull parts from accumulation in order
 IntelliTrak 500 Series Automotive Front End Module Assembly Overhead Conveyor

Complex assembly made easy, increasing TAKT time and competitive advantage.

Opportunity:
A supplier of automotive interiors needed an overhead conveyor system for their new facility.
Solution:
IntelliTrak designed, manufactured and installed a 500 Series Overhead Conveyor System that included 41 assembly workstations with 4 test zones and level 2 software
controls to manage workstations. The new overhead conveyor not only freed up floor space, but gave them a real competitive advantage by allowing them to meet an extremely fast TAKT time of 75 jobs per hour.
IntelliTrak 500 Series Automotive IP Instrument Panel Assembly Overhead Conveyor

IntelliTrak 150 Series—the ideal solution for a Tier 1 automotive supplier needing accumulation, staging and product transfer.

Opportunity:
A supplier of automotive interiors needed a conveyor system that would store 12 hours of production, accumulate efficiently, handle left-handed and right-handed IP assemblies, with a limited footprint (keeping walkways between lanes), while meeting a 45 second TAKT time.
Solution:
The IntelliTrak 150 Series Overhead Conveyor, with a max load of 150 lbs. and 100+ fpm, was tailor-made for this application. IntelliTrak designed, manufactured and installed approximately 3,000 ft. of conveyor, a mezzanine, 2 levels of storage, 693 carriers, with a line speed of 45 ft./min., and incline/decline speed at 60 ft./min.
Automotive Instrument Panel Storage and Retrieval Overhead Conveyor- IntelliTrak 150 Series

Unused overhead space + IntelliTrak 150 Series = the ideal solution for accumulation, staging and product transfer.

The IntelliTrak 150 Series Overhead Conveyor is ideal for lower weight, higher speed applications, and excellent for accumulation, staging and product transfer.

IntelliTrak was able to optimally use previously unused overhead space by moving assembled parts up to the mezzanine for storage. With a custom-designed product carrier, the conveyor is extremely flexible, making it able to handle several different versions of product.

Automotive IP Instrument Panel Storage and Retrieval Overhead Conveyor

Streamlining production with an IntelliTrak Overhead Conveyor System reduced delivery time by 75%. Repeat customer: 41 systems in 25 facilities.

Opportunity:
Long delivery times and inaccuracies were all too common for this manufacturer of blinds. With an outdated system that required elevation to buffer between processes, outfeeds that used gravity to pull the carriers away from the main line, and no automated production sequencing or MES solution, an IntelliTrak 500 Series was the ideal solution.

Solution:
IntelliTrak designed, manufactured and installed a custom IntelliTrak 500 Series Overhead Conveyor. Not only did they save valuable floor space by going vertical, production equipment was organized for better manufacturing flow and an MES solution was implemented to track production.

Window Treatment Assembly Overhead Conveyor IntelliTrak 500 Series

Results:
Delivery turnaround was reduced by 75% from 8 weeks to less than 2 weeks. The system has worked so well for this manufacturer that they’ve installed 41 systems in 25 facilities worldwide.


Custom-designed conveyor system provides an efficient, clean work environment for manufacturer of LCD displays

Opportunity:
Manufacturer of large LCD displays, using a manual line for assembly, needed a more efficient and ergonomic solution with greater flexibility and quality control.
Solution:
IntelliTrak’s engineers custom-designed a 1500 Series Overhead Conveyor with vertical lifts on each end (for empty carrier return overhead), 14 work stations, incline for ergonomic assembly, a quality control workstation and spur for rework. Forward/reverse capabilities and zone control gave the customer the flexibility they needed. And the chainless friction drive provided the clean work environment—an important factor when working with highly sensitive LCD controls.
LCD Display Assembly Overhead Conveyor IntelliTrak 1500 Series with vertical drop lift

A more efficient system with a smaller footprint.

Opportunity:
Having already installed an IntelliTrak Conveyor System in another location, when it came time to purchase a conveyor system for a new facility with limited floor space, the decision was easy for this supplier of automotive interiors.
Solution:
IntelliTrak designed, manufactured and installed a custom inverted (floor-mounted) conveyor with an over/under design to make the most of their limited floor space. The system consisted of 5 assembly stations at floor level, with cantilever lifts on each end for elevated return of empty carriers. A more efficient system, with a smaller footprint.
Automotive Console Assembly Conveyor IntelliTrak 1500i Inverted Series with vertical drop lift

IntelliTrak 150 Series and unused overhead space—an ideal solution for accumulation, staging and product transfer.

Opportunity:
A supplier of automotive interiors needed a conveyor system that would store 12 hours of production, accumulate efficiently, handle left-handed and right-handed IP assemblies, with a limited footprint (keeping walkways between lanes), while meeting a 45 second TAKT time.
Solution:
The IntelliTrak 150 Series Overhead Conveyor, with a max load of 150 lbs. and 100+ fpm, was tailor-made for this application. IntelliTrak designed, manufactured and installed approximately 3,000 ft. of conveyor, a mezzanine, 2 levels of storage, 693 carriers, with a line speed of 45 ft./min., and incline/decline speed at 60 ft./min.
Automotive Instrument Panel Storage and Retrieval Overhead Conveyor - IntelliTrak 150 Series

Optimal use of overhead space for storage.

The IntelliTrak 150 Series Overhead Conveyor is ideal for lower weight, higher speed applications, and excellent for accumulation, staging and product transfer.IntelliTrak was able to optimally use previously unused overhead space by moving assembled parts up to the mezzanine for storage. With a custom-designed product carrier, the conveyor is extremely flexible, making it able to handle several different versions of product.

Automotive IP Instrument Panel Storage and Retrieval IntelliTrak 150 Series Overhead Conveyor

For one large manufacturer of construction equipment, IntelliTrak’s modular conveyor system is an industry game-changer.

Opportunity:
Large manufacturer of construction equipment needed a conveyor system for a new facility. They chose the IntelliTrak 3500 Series largely because of its promise of extreme modularity.
Solution:
IntelliTrak’s friction drive system (no chains) and modular support structure (bolted, not welded), is easily modified, expanded and moved—the entire system if required!As parts change and new models are developed or quantities changed, this system is able to easily move with those changes. Not only that, but the system’s forward/reverse capabilities and the use of spurs, all served to improve processes, reduce downtime and increase productivity.All components are standardized, so that moving forward, further installations and modifications will be simple with minimal project management required.
Perfect example of IntelliTrak’s modularity:
In one weekend, at the customer’s request, IntelliTrak added switches and a cooling lane, all while production continued, with no downtime and no overtime.
Heavy Industrial Finishing Overhead Conveyor IntelliTrak 3500 Series with heavy duty vertical drop lift and shuttle

Custom-designed conveyor system provides an efficient, clean work environment for manufacturer of LCD displays

Opportunity:
Manufacturer of large LCD displays, using a manual line for assembly, needed a more efficient and ergonomic solution with greater flexibility and quality control.
Solution:
IntelliTrak’s engineers custom-designed a 1500 Series Overhead Conveyor with vertical lifts on each end (for empty carrier return overhead), 14 work stations, incline for ergonomic assembly, a quality control workstation and spur for rework. Forward/reverse capabilities and zone control gave the customer the flexibility they needed. And the chainless friction drive provided the clean work environment—an important factor when working with highly sensitive LCD controls.
LCD Display Assembly Overhead Conveyor IntelliTrak 1500 Series with vertical drop lift