GymBeam: Automated Conveyor System for High-Efficiency E-commerce Logistics

Smarter Logistics for a Fitness E-commerce Leader

For GymBeam, a Slovak e-commerce giant setting the pace in fitness and healthy lifestyle across Europe, we designed and delivered an automated conveyor system tailored for their AutoStore automated warehouse.

Performance You Can Rely On – Up to 2,500 Shipments per Hour

Thanks to advanced automation, GymBeam benefits from swift and precise order fulfillment. Our system efficiently handles up to 2,500 shipments per hour, enabling the company to keep pace with rising demand and consolidate its leadership position in the market.

Our comprehensive delivery included an integrated technical solution, PLC and HMI software development integrated with the customer’s IT system, creation of electrical documentation and layouts, production of switchboards and operator panels, complete electrical installation in Košice, commissioning of the system with testing, operator and maintenance training, and ongoing post-handover assistance.

The mechanical components of the project were designed and executed by our strategic partner and general contractor of this project, TMT a.s. Chrudim.

Intelligent Solution for Efficient Order Picking

We implemented a dual-level conveyor system designed to distribute empty boxes to AutoStore stations. The system currently services 10 picking ports, with plans to expand to up to 20 ports in the near future.

Each empty box is automatically labeled with an internal tag and paired with a specific order. Once filled with products, the box transforms into a fully-fledged shipment, which is subsequently weighed, packaged by an automatic packing machine, and labeled with a shipping label. Finally, shipments are routed to an outgoing sorter, ensuring rapid and accurate dispatch to the expedition area. The controlled shipment flow system guarantees precise timing and smooth operation.

Primary Automation Components Utilized:

• Safety control system SIMATIC S7-1500, distributed peripherals SIMATIC ET200SP.
• Visualization via SIEMENS Unified Comfort Panels.
• Profinet and IO-Link communication buses.
• Schneider Electric Altivar frequency converters.
• Automatic labeling applicators.
• Keyence 1D/2D code readers.
• Mettler Toledo dynamic scales.
• SEW asynchronous drives and Interroll 24V drives.
• Signal acquisition through Profinet/IO-Link TURCK units.
• TURCK instrumentation.
• FESTO pneumatic components.
• SICK safety components.

Scope of Our Delivery Included:

• Technical solution development.
• Creation of functional analysis for the control system.
• Electrical documentation and automation layouts.
• PLC and HMI software development.
• Communication integration with the customer’s IT system.
• Communication with machines responsible for folding and closing boxes.
• Production of switchboards and operator panels.
• Supply of all electrical installation materials.
• Electrical installation at the customer’s facility in Košice, Slovakia.
• System commissioning and comprehensive functionality testing.
• Training of operators and maintenance staff, including creation of manuals.
• Post-delivery customer support.