Projects ToteTracker for Warehouse Traceability

Taking Logistics to the Next Level with Scorpion Vision’s Tote Tracking Solutions

Hello everyone! Julen Wilson-Frade here, and today I want to dive into a critical area for modern logistics – tote tracking. At Scorpion Vision, we’ve been at the forefront of developing advanced imaging systems that bring unprecedented efficiency and accountability to warehouse operations. Let’s explore our range of ToteTracker solutions, designed to meet various needs and challenges.

ToteTracker System in operation at a UK warehouse.

ToteTracker system in operation at a UK warehouse. Note, the light source with a colour camera on the gantry and the two barcode scanners at each side of the conveyor.

What is ToteTracker+?

ToteTracker+ is a high-speed imaging system designed to capture and record images of products as they move along conveyor systems and are dropped into tote bins. Imagine having a visual record of every item that goes into each tote, providing you with unparalleled tracking and accountability. This system is engineered to operate inline with existing conveyor systems, creating real-time images of product flow.

The Evolution of Tote Tracking

The Problem:

The product is automatically dropped into tote bins, and each one represents a customer order. After the tote has passed through the ToteTracker, the tote is then packed and sent to the customer. Occasionally, the customer complains that the order is incomplete or damaged. The warehouse operator has no way of verifying that the contents of the tote bin were correct at the time of departure, so any discrepancies have to be accepted, and this can be expensive.

This is where ToteTracker comes in. Now the warehouse operator has full traceability; when the next customer complaint comes in, the operations department can recall every single tote bin image using date, time or barcode information. So now, any discrepancies between the warehouse and the customer can be either disputed or agreed upon.

We understand that different clients have different requirements. That’s why we’ve developed multiple versions of our tote tracking systems. Let’s start with the foundational system, ToteTracker. This system was specifically designed for a nationwide pharmaceutical distribution warehouse and focuses on:

  • Barcode Scanning and Image Capture: Reading barcode labels on totes triggers high-resolution colour cameras to capture images of the tote contents.
  • Real-Time Archiving: Images are saved with tracking information derived from code readers and stored in cloud storage for easy retrieval.
  • Dual System for Two Conveyors: Managed from a central controller with dedicated hardware for each line.

It laid the groundwork for enhancing traceability and accountability within logistics hubs. The focus here was on reliably capturing images triggered by barcode data, creating a basic digital record for each tote.

ToteTracker system on a conveyor belt with barcode scanner

The system uses two HIKROBOT ID2000 series high-speed barcode scanners.

Expanding Capabilities with ToteTracker+

Building on the success of ToteTracker, we developed ToteTracker+. This system is a significant leap forward, designed for high-speed imaging of products as they move rapidly on conveyor systems and drop into tote bins. Here’s what sets ToteTracker+ apart:

  • High-Speed Image Capture: Up to 60 frames per second with a strobing light to eliminate motion blur and capture the fast-paced flow of products.
  • Triggered Recording with Proximity Sensors: Cameras begin recording before the batch arrives at the imaging zone, ensuring every moment is captured.
  • RAID-Based Mass Storage: Gigabytes of image data are stored securely on a network storage system, providing a robust archive for investigations.
  • Time and Date-Based Image Management: Easily find and review product flow data through an intuitive management system.
  • Potential for AI Integration: Future upgrades can leverage the captured high-quality images for automated recognition, counting, brand recognition, and even damage detection.

ToteTracker+ is ideal for operations that need to track fast-moving products and require detailed visual records for audit trails and issue resolution.

the main control panel for the ToteTracker system

The main control panel for the ToteTracker system.

KEY COMPONENTS OF THE TOTETRACKER® SYSTEM INCLUDE:

  • Scorpion Vision Software: Managing image capture, labelling, and storage.
  • Scorpion Watchdog: Ensuring continuous operation by automatically restarting the software.
  • High-Resolution Cameras and Barcode Readers: The latest in data matrix and barcode reading from HIKROBOT.
  • Detailed Operational Procedures: Including directory selection, drive space monitoring, and software backup procedures.

Why Choose Scorpion Vision’s Tote Tracking Solutions?

  • Tailored Solutions: We understand that each client has unique needs, and we are committed to providing bespoke systems that address those needs precisely.
  • Advanced Technology: We use state-of-the-art cameras, lighting, and software to ensure high-quality image capture and reliable performance.
  • Future-Proofing: Our systems are designed with potential for future upgrades, such as AI integration, to ensure they remain relevant and effective.
  • Comprehensive Support: We offer Service Level Agreements (SLAs) with priority response times and engineering support to keep your systems running smoothly.

Get in Touch!

If you’re looking to improve your logistics operations with advanced tote tracking solutions, Scorpion Vision has the expertise and technology you need. Whether you require a basic barcode scanning system or a high-speed, AI-ready imaging solution, we can provide a tailored system that meets your exact requirements.

Feel free to reach out to me at [email protected] to discuss your needs and explore how we can help improve traceability and reduce your costs!

GET IN TOUCH

We are always delighted to hear from our customers. If you’d like to ask a question, make an enquiry or request support, please contact us through one of the methods below or by using the enquiry form.

Telephone: +44 (0) 1590 679333
Sales: [email protected]
Technical: [email protected]

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