For over 40 years, Custom Conveyor has been engineering warehouse conveyor systems exclusively for the glass manufacturing and distribution sector. As a veteran-owned business and active member of both the National Glass Association and Conveyor Equipment Manufacturers Association (CEMA), we’ve transformed warehouse operations across North America. We’ve seen firsthand how properly engineered warehouse systems reduce labor costs, minimize product damage, and maximize storage capacity – and how generic solutions fail to meet the unique demands of glass handling.
Since 1984, Custom Conveyor has engineered warehouse solutions for glass facilities ranging from 20,000 square foot distribution centers to 500,000 square foot manufacturing complexes. Our veteran-owned company has encountered virtually every challenge warehouses face when storing, sorting, and shipping glass products.
Case Example 1: High-Density Glass Storage In 2021, we worked with a flat glass distributor whose warehouse could only utilize 62% of cubic space due to access limitations. Our solution involved multi-level pick modules with specialized glass handling conveyors and automated storage/retrieval systems. Result: Storage capacity increased by 78% in the same footprint, while picking accuracy improved to 99.7%.
Case Example 2: Order Consolidation Complexity When a major architectural glass supplier needed to consolidate orders containing 20+ different SKUs, traditional sortation wasn’t viable due to fragility concerns. Working with our CEMA partners, we developed a zone-based accumulation system with intelligent routing. The system now processes 400+ mixed orders daily with less than 0.5% error rate.
Case Example 3: Seasonal Surge Management One client’s warehouse experienced 300% volume increases during construction season. Our flexible conveyor design included portable sections and expandable accumulation zones. This taught us that warehouse systems must adapt to demand fluctuations without compromising the careful handling glass products require.
Our engineering team includes certified professionals with specialized training validated by our active memberships in both the National Glass Association and CEMA. This expertise, refined over four decades, matters because glass warehouse operations require understanding of unique storage challenges, fragility factors, and space optimization.
Warehouse Flow Optimization With 40+ years designing glass warehouses, we understand how to maximize throughput while minimizing handling. Our solutions incorporate gravity flow where possible, powered sections only where necessary, and accumulation zones that prevent product damage. Every layout reflects lessons learned from thousands of installations.
Multi-Level System Design We engineer complete pick modules and mezzanine systems that integrate seamlessly with conveyor networks. Our CEMA-certified engineers calculate not just structural loads, but also vibration dampening for sensitive glass products. Each design optimizes vertical space while maintaining safe, efficient access.
WMS Integration Excellence Four decades of experience means we’ve integrated with every major warehouse management system. From RF picking to voice-directed operations, our conveyors communicate seamlessly with your WMS. We handle the complexity of zone routing, wave planning support, and real-time inventory tracking.
Climate Control Considerations Glass products require stable environments. Our warehouse systems include features like heated roller sections for cold storage applications, drainage systems for condensation management, and expansion joints that accommodate temperature fluctuations without affecting alignment.
Since 1984, we’ve maintained exceptional performance metrics across glass warehouse installations. As a veteran-owned business and active member of both the National Glass Association and CEMA, we deliver consistent, measurable results:
Labor Efficiency Gains Warehouses using our systems report 40-60% reductions in labor hours per unit shipped. This efficiency comes from ergonomic design that eliminates unnecessary lifting, intelligent routing that minimizes travel distance, and accumulation strategies that batch work effectively. One glass distributor reduced their warehouse team from 18 to 11 while increasing daily shipments by 35%.
Inventory Accuracy Enhancement Our integrated scanning and verification systems help clients achieve 99.5%+ inventory accuracy. Dedicated inspection conveyors with integrated scales catch discrepancies before shipping. RFID tracking zones provide real-time location data. These capabilities, refined over 40 years, virtually eliminate shipping errors.
Space Utilization Optimization Clients typically gain 50-80% more storage capacity through our vertical solutions and optimized flow patterns. We achieve this through narrow-aisle designs for glass racks, overhead conveyor systems that free floor space, and dynamic storage assignments that adapt to changing inventory mix.
Damage Reduction Results Glass breakage in our warehouse systems averages below 0.3% – compared to industry averages of 2-4%. We accomplish this through cushioned stops at every accumulation point, variable speed controls that prevent abrupt starts/stops, and photo-eye spacing that maintains safe product separation.
Our warehouse engineering process, refined over 40 years and 1,800+ warehouse projects, ensures optimal outcomes:
Our CEMA-certified engineer spends 2-3 days analyzing your current operations, including time studies of key processes, spaghetti diagrams of material flow, volume analysis by SKU category, and ergonomic assessments of work areas. We use RFID tracking to map actual vs. theoretical paths.
Using AutoCAD and warehouse simulation software, we model multiple layout options and test performance under various scenarios. Our designs account for seasonal variations, future SKU additions, labor availability constraints, and integration with existing infrastructure. Each simulation runs thousands of order profiles to identify optimal configurations.
Every warehouse design includes a detailed implementation plan that minimizes operational disruption. This plan identifies temporary conveyor sections for continuity, weekend installation windows, and zone-by-zone commissioning schedules. As a veteran-owned company, we apply military logistics principles to ensure smooth transitions.
We don’t consider a project complete until performance metrics are verified. This includes time studies comparing actual to projected rates, accuracy audits across all zones, safety inspections by certified professionals, and efficiency tracking for 90 days post-installation.
Having served the glass industry for over four decades, we’ve witnessed and driven the evolution of warehouse technology. Our veteran-led approach combines proven reliability with forward-thinking innovation.
AI-Powered Slotting Optimization Drawing on 40+ years of warehouse data, we’re implementing machine learning algorithms that continuously optimize product placement. The system analyzes order patterns, seasonality, and product velocity to suggest slotting adjustments that reduce travel time by up to 30%.
Sustainable Warehouse Design We’ve pioneered energy-efficient warehouse systems that reduce power consumption by 45% through LED lighting with motion sensors, energy-recovering conveyor drives, and solar panel integration on pick module roofs. These innovations meet the sustainability goals our National Glass Association members increasingly prioritize.
Flexible Automation Readiness Recognizing that warehouse automation is evolving rapidly, we design every system for future enhancement. Standard preparations include power and data drops for future robotics, conveyor heights compatible with AMRs, and control systems with open architecture. Your warehouse stays competitive as technology advances.
The Custom Conveyor team brings together over four decades of specialized experience, led by veterans who understand the importance of precision, reliability, and continuous improvement.
Warehouse Design Specialists
Implementation Experts
Ongoing Support Team Through our memberships in the National Glass Association and CEMA, our support team maintains current certifications in warehouse safety, emerging technologies, and best practices. We provide lifetime access to engineers who understand your specific system.
Every Custom Conveyor warehouse system comes with comprehensive quality assurance and performance guarantees:
Design Validation
Construction Standards
Performance Metrics
Training and Documentation
As a veteran-owned business serving glass warehouses nationwide for over 40 years, we combine military precision with deep regional understanding.
From a tempered glass warehouse in Phoenix managing 120°F summers to an insulated glass distributor in Minnesota handling -30°F winters, we’ve successfully implemented solutions across diverse climates. Each design reflects regional requirements while maintaining our unwavering standards.
When you choose Custom Conveyor for warehouse solutions, you’re partnering with a veteran-owned company that’s been optimizing glass storage and distribution since 1984. Our active memberships in the National Glass Association and CEMA ensure we’re current with industry standards, while our four decades of hands-on experience means we’ve solved challenges across every warehouse type and size.
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Custom Conveyor – Veteran-owned since 1984 | National Glass Association Member | CEMA Member | Your trusted partner in warehouse optimization
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