Interroll enters a new era in material handling with MCP PLAY

Just in time for the start of LogiMAT, Interroll, the world's leading provider of material handling solutions, is heralding a paradigm shift in automated conveyor systems. With MCP PLAY, conveyor systems can be implemented more easily and quickly, operated more cost-effectively and energy-efficiently, and achieve up to 100% higher throughput.

Since its introduction in 2014, Interroll's Modular Conveyor Platform (MCP) and control interfaces at the BUS level have set global standards. The platform-based modules, consisting of roller conveyors, belt conveyors in various designs, transfers, diverts, curves, lifts, and more, can flexibly handle almost any conveying task for objects up to 50 kg. Complex conveyor systems with multiple zones have traditionally been controlled using the established Zero Pressure Accumulation (ZPA) method. Alternatively, the IO mode was used, which required additional programming effort for PLCs.

Faster, easier, smarter

With the MCP PLAY feature, an addition to the standard ZPA or IO mode, conveyor systems can now be configured more easily and controlled in a decentralized, embedded manner. MCP PLAY reduces programming and commissioning efforts and eliminates the "one package per zone" constraint, enabling increased throughput and lower energy consumption. Additionally, the new Interroll commissioning tool allows integrators and operators to check system status, change configurations, and enable tracking features. All functions and workflows are pre-configured in the Interroll layouter tool for each MultiControl unit and can be quickly assigned and installed during commissioning.

MCP PLAY significantly reduces the complexity and programming effort involved in planning, installing, configuring, and analyzing errors in conveyor systems. This innovation lowers costs and reduces dependence on PLC programming specialists.

Panta Rei – everything flows

A key innovation of MCP PLAY is the "Flowing Merge" function. The innovation lies in the decentralized and embedded control of this functionality - instead of having to program this with a lot of effort, it comes out of the box and just needs to be configured. In place of stopping material before merging two conveyor lines, MCP PLAY reduces the speed in the section before the merge, allowing the material to continue flowing. This revolutionary approach increases throughput and enhances overall system efficiency to a new level. It also reduces energy consumption and power requirements by avoiding starting currents and peak loads, while minimizing noise levels and mechanical wear—all contributing to improved sustainability.

Up to 100% more throughput

MCP PLAY delivers substantial gains in efficiency and throughput. With the "Adjust to Gap" function, items can be transported at shorter intervals along the conveyor line. According to calculations by Fraunhofer IML, continuous flow, higher average speeds, and increased conveying capacity can boost system throughput by up to 100% compared to the ZPA solution. At the same time, their research indicates energy consumption can be reduced by up to 30% at high throughputs.

Intuitive software tools

MCP PLAY is designed as a modular add-on to the MCP hardware and can be applied to both new and existing MCP installations using the 24V/48V RollerDrive in combination with the MultiControl with BUS interface. The software offers an intuitive user interface and supports all major WMS and IoT shop floor systems while incorporating robust cybersecurity measures. The decentralized control reduces data exchange within the system environment, resulting in lower latency and improved monitoring, responsiveness, and system flexibility.

Fast return on investment

MCP PLAY enhances the efficiency of conveyor systems, from small applications to high-performance environments. Complex projects requiring high throughput or advanced tracking capabilities can be implemented more quickly. The cost and efficiency benefits optimize the return on investment (ROI) and shorten the payback period, opening new possibilities for conveyor system applications.

MCP PLAY's modular plug-and-play design allows easy adaptation of system layouts and settings to meet changing requirements. This feature is particularly beneficial for e-commerce merchants managing seasonal demand fluctuations and for third-party logistics (3PL) providers facing frequent customer changes. By digitalizing the entire process—from planning and ordering to simulation, installation, and commissioning—MCP PLAY enables system integrators to respond to their customers' needs more rapidly.

Markus Asch, CEO of Interroll, explains: With MCP PLAY, Interroll is setting new standards in material flow and once again proving its innovation leadership in the market. MCP PLAY is a central part of our strategic vision to deliver modular and future-proof solutions that enable our customers to grow through innovation, reduce costs, and gain a clear competitive advantage.

This article was originally published by Interroll.