How a custom conveyor system increased fulfillment to 5,000+ orders/day

The Feed, the world’s largest sports nutrition marketplace for endurance athletes, required a conveyor system to seamlessly integrate two existing automation systems and manage thousands of daily orders. While many providers urged The Feed to adapt its processes to fit their solutions, Vention took a different approach—designing a fully customized system tailored to The Feed’s unique needs. Even more impressively, the full solution was delivered and implemented in just 6 weeks, compared to the 40 weeks quoted by other companies.

To kick off the project, The Feed used MachineBuilder to create a prototype design. This 3D design created a digital twin, offering a near-accurate depiction of how the solution would operate in the real world—all within the cloud.

With the help of MachineLogic’s Physics Engine, The Feed was able to simulate their digital twin in a highly realistic virtual environment before deployment. Using a box input module, they configured dynamic parameters for box insertion on conveyors, including dimensions, insertion rate, weight control, and part placement. For a complex conveyor project like The Feed’s, this provided a much more reliable simulation environment to test and debug program behavior.

By simulating real-world operations in the cloud, the team was able to verify and de-risk deployment, knowing that the final solution would meet their needs and perform as expected.

In just 6 weeks, The Feed had a fully operational conveyor system up and running on its manufacturing floor. This allowed them to increase order fulfillment to over 5,000 orders per day while reallocating 15 workers to more high-value tasks.

As an automation partner, Vention not only delivered 34 weeks faster than competitors’ quotes, but they also provided hands-on support throughout implementation, ensuring the solution ran as expected. The Feed praised the commitment, saying, “They told us, ‘We’re going to stay here until this is perfect.’ And they did. That’s why we’ll be coming back as a future customer.”