Cross-Laminated Timber Conveyor System: How Almac Solved Element 5’s Heavy Panel Transportation Challenge
Project Details: Element 5 CLT Manufacturing Facility | Project #33751 | 60′ x 12′ Chain Driven Live Roller Conveyor System
About Element 5: Leading CLT Panel Manufacturer
Element 5 stands as a premier manufacturer of Cross-Laminated Timber (CLT) panels, producing sustainable building materials that serve as eco-friendly alternatives to traditional concrete and steel construction. Their state-of-the-art manufacturing facility produces custom CLT panels in impressive dimensions:
- Length: Up to 52 feet
- Width: Up to 12 feet
- Thickness: Up to 12 inches
- Applications: Structural walls, floors, roofing systems, and commercial building components
These engineered wood panels represent the future of sustainable construction, offering superior strength-to-weight ratios while significantly reducing carbon footprints compared to conventional building materials.
The Manufacturing Challenge: Moving 16,000-Pound CLT Panels
Element 5 faced a critical material handling challenge in its production facility. The company needed to transport full-size CLT panels weighing up to 16,000 pounds each between different manufacturing stations while crossing through building column lines.
Specific Transportation Requirements:
- Move panels from North-South processing equipment to East-West production lines
- Navigate around structural building columns and support beams
- Maintain panel integrity during transportation
- Integrate seamlessly with existing upstream equipment
- Ensure 24/7 operational reliability
Why Standard Overhead Cranes Weren’t Sufficient
While overhead crane systems offer advantages for lifting and reorienting heavy panels, they present significant limitations:
- Structural constraints: Runway beams were restricted by building column lines
- Limited coverage area: Cranes couldn’t effectively cross between different facility zones
- Safety concerns: Heavy 16,000-pound loads suspended overhead posed risks to work zones below
- Operational inefficiency: Time-consuming process requiring rigging, lifting, moving, positioning, and de-rigging for each panel
- Speed limitations: Conveyor systems move panels faster than complex crane operations
Almac’s Engineering Solution: Integrated Conveyor and Transfer System
Our engineering team designed a comprehensive material handling solution combining two specialized systems:
Chain Driven Live Roller Conveyor (CDLR)
- Dimensions: 60 feet long × 12 feet wide
- Capacity: Handles full-size CLT panels and billets
- Operation: Receives panels from the upstream North-South processing equipment
- Construction: Heavy-duty design rated for 16,000+ pound loads
Mobile Transfer Trolley System
- Function: Carries the entire CDLR conveyor with loaded panels
- Movement: East-West axis transportation crossing building column lines
- Track system: Floor-mounted rails anchored to facility foundation
- Integration: Automated controls communicate with existing production equipment
Key Engineering Features:
- Dual-axis movement capability (North-South conveyor + East-West trolley)
- Heavy-duty construction suitable for extreme weight loads
- Automated safety systems prevent operational conflicts
- Seamless integration with Element 5’s existing manufacturing workflow
- Ease of operation – CLT panels require no handling by operators
Implementation Results: Reliable 24/7 Operation
The installed system has exceeded performance expectations since commissioning:
Operational Benefits:
- Zero downtime for panel transportation between production stages
- Virtually maintenance-free operation according to client feedback
- Complete compatibility with all CLT panel sizes manufactured on-site
- 24/7 reliability supporting continuous production schedules
Ongoing Partnership Success:
Element 5 has expanded its relationship with Almac, commissioning additional conveyor projects to optimize its CLT manufacturing and finishing processes further.
Client Testimonial: VP Manufacturing Engineering Perspective
“As a valued partner of Element5, Almac has provided robust, reliable solutions. The Almac team works cohesively with the Element5 engineering team to ensure solutions are designed to meet the design goals, are fully tested prior to installation and have the reliability required to operate 24/7.”
— Chris Latour, VP Manufacturing Engineering, Element 5
Why This Solution Works: Technical Expertise Meets Real-World Application
This project demonstrates Almac’s in-depth understanding of the challenges associated with heavy industrial material handling. Our 30+ years of conveyor system design experience enabled us to:
- Analyze complex spatial constraints within existing manufacturing facilities
- Engineer custom solutions that work around structural limitations
- Integrate seamlessly with the client’s existing production equipment
- Deliver maintenance-free systems that operate reliably under extreme conditions
Need a custom material handling solution for your manufacturing facility? Contact Almac’s Sales or Engineering team at (905) 713-1377 or request a consultation to discuss your specific requirements.
