Solutions for Automatic Identification Systems image

Solutions for Automatic Identification Systems

As the pace of production and logistics continues to accelerate and the demands for 100% accuracy and accountability increase, Morrell continues to serve as its customers’ single-source solution for all of their motion, control, and logistics needs. Morrell’s automatic identification systems are increasingly utilized to help its customers revolutionize their end-of-production logistics. We have extensive experience in the successful design, engineering, prototyping, installation, and execution of automatic identification solutions. Using a variety of digital sensors, barcode scanners, conveyors, and other robotic implements, our solutions identify and track pallet content, label the pallet, update inventory records, and track pallet shipping. Each of these steps is coordinated within a central operations database that can be scaled to coordinate automated systems within the scope of an entire enterprise. Our expertise, coupled with our relationships with leading automation component suppliers, allows us to design and install custom solutions over an incredible range of industries.

Engineering, Manufacturing, and Quality Support

Morrell offers comprehensive solutions for automatic identification systems. We consult with our customers to fully understand their needs, design a custom solution, properly identify and install the required systems and components, and troubleshoot to ensure success. Since automatic identification systems are a crucial aspect of modern logistics, it is imperative to ensure the integration of the systems and components translate into efficient, safe, and productive workflows. Our facility planning and virtual prototyping capabilities allow customers to discern how these systems will function within their existing or new operations well before final implementation. We pride ourselves on our reputation, which is built upon nearly 30 years of experience throughout virtually every industrial sector. This experience, when paired with our top-notch component suppliers, translates to success for our customers.


Worker safety is paramount in automated environments, and Morrell’s systems are designed with this in mind. Our engineers study the customer’s environment to determine the optimal placement of automatic and emergency shut-off switches. We specify and install protective barriers on accessible conveyors, lifts, and other mechanized components. Other safety benefits occur further down the line. Automatic palletizing allows the collation and packaging of products within specific parameters, guaranteeing uniform and secure bundles that conform to shipping regulations. The majority of distribution operations include a mix of automated and manual processes. We generate solutions that promote the safe interaction between humans and machines which is key to efficient and effective workflows. In addition, product tracking provides the ability to follow a given product from the factory to the consumer, an essential feature for quality control and absolutely critical in the event of a product recall.

Product Sizing & Quantification

As a pallet is stacked with product or retrieved from inventory prior to shipping, digital sensors measure the stack’s dimensions. Based on known product dimensions pre-programmed into the overall logistics management process controls, these data are used to determine exact product size and quantity. This is the initial step of a comprehensive automatic identification system and serves to ensure both proper orientation and order integrity well before its inclusion into the process. The product sizing and quantification information is relayed to the central operations database, which communicates with other parts of the production process to ensure synchronization with just-in-time production and just-in-time delivery protocols. Morrell works extensively with its customers to determine the proper solutions for a given environment. For example, dusty conditions, dark-colored products, and reflective surfaces are not conducive to laser sensors. In these situations, ultrasonic sensors are specified for this function.

Bulk Product Labeling

After the order’s accuracy has been verified, the pallet moves via conveyor to the wrapping station, where it is prepared for secure shipping, and then via conveyor to the bulk product labeling station. Here, the pallet receives a two-dimensional (2D) barcode and radio-frequency identification (RFID) tag. These contain a variety of information, including date of manufacture, shift of manufacture, sell by date, lot number, location of manufacture, ship to location, operator, etc. This step is critical as an additional check for order accuracy and also for proper tracking of product distribution. This is especially important in relation to product quality issues, including the event of a product recall. Morrell has extensive expertise with barcode and RFID technology, which allows our customers to track 100% of their products from shop floor to retail store and all venues in between.

Inventory Management

After the pallet receives bulk product labels, a mobile automated crane picks up the pallet and stages it prior to shipping. The crane is equipped with RFID interrogators and/or long-range, two-dimensional bar code readers that identify the pallet. It communicates the pallet’s new location to the central operations database. The pre-shipping, staging process is fully automated by the central database, and is based on algorithms that optimize order fulfillment in a just-in-time shipping and distribution environment. Morrell’s comprehensive approach is especially valuable when designing solutions that include the automation of material handling equipment, like cranes and automated guided vehicles. Not only do we design the automated system, we work with all of the suppliers, specifying and procuring sensor and scanner components, cranes and conveyors, and more to ensure all of the components work properly when the system goes on line.

Shipping Documentation

Using a two-dimensional bar code reader or RFID interrogator (either hand-held or fixed), the pallet undergoes a final order check and is recorded as “shipped” just before it leaves the facility. This operation is the ultimate validating and verification step of the entire process, as it checks the order information contained in the pallet’s barcode or RFID with the order data contained in the central operations database. Morrell understands that these additional validation and verification steps are essential in assuring accurate and quick delivery, a key component in manufacturing efficiency.

Systems Communications

All of the systems and components utilized within the five steps above use the same software and communications protocols, which are integrated into a central operations database that can be scaled to manage a single process, a single facility, or the entire enterprise. Operations personnel can monitor and troubleshoot the system on-site or off-site. Morrell offers a variety of communication protocols to mesh with its customers’ existing and future needs, including Ethernet, ProfiBus, ProfiNet, DeviceNet, or any customer PLC. In addition, all of Morrell’s auto identification components are available with onboard web servers that allow for remote diagnostics.

Manufacturers seek efficiencies in all phases of production. Morrell’s automated identification systems allow full automation of end-of-production processes, from palletizing to transport. We offer extensive engineering experience and a top-notch suppler network. We are proud of our comprehensive approach, covering all aspects of the project from design to installation to support. Morrell’s customers are using our state-of-the-art, fully-automated solutions to realize incredible cost savings and quality control in a multitude of industries. Our expertise, coupled with our relationships with leading automation component suppliers, allows us to design and install custom automatic identification solutions to take distribution operations to the next level.

Engineering, Manufacturing, and Quality Support:
  • Facility Planning
  • Process Planning
  • Product Planning
  • Reverse Engineering
  • Laser & White Light Scanning
  • Ergonomic Studies
  • Virtual Prototyping
  • Component Sizing & Selection
  • Engineering Support
  • Manufacturing
  • Electrical Engineering
  • Field Wiring
  • Electrical Control & Panel Design
  • Full System Installation
Solutions for Automatic Identification Systems:
  • Safety
  • Product Sizing & Quantification
  • Product Identification
  • Bulk Product Labeling
  • Inventory Management
  • Shipping Documentation
  • Systems Communication
Engineering, and Build Standards:
  • UL Certified
  • NFPA
  • CE
  • CUL
  • OSHA
  • 2003 ISO 9000/2000
  • 2004 TE 2000
  • 2006 ISO 9001:2000
  • 2009 ISO 9001:2008

Additional Information:

Automatic Identification Systems PDF thumbnail
Download our PDF on Automatic Identification Systems

We Proudly Support Our Suppliers