Material Handling Case Studies

Distribution Center Saves Over $1 Million Dollars in Replacement Costs with All-Composite Conveyor Diverter Arms

A client, operating within the material handling industry, came to Globe Composite to find a solution to mitigate costs associated with underperforming conveyor diverter arms. Approximately 5,000 diverter arms were being used between two facilities to handle over 350 million packages a year, so any downtime was disruptive to critical sorting operations and costly.

With packages weighing anywhere upwards of 80 pounds, an incredible amount of stress was causing the part, made of reinforced aluminum, rigid plastic, and steel, to deform and crack. After several years of expensive and unsuccessful efforts to extend the life of their product, we worked with our client to develop the All-Composite Conveyor Diverter Arm.

In this case study you will find the following:

  • Our Process: How We Went from Problem to Solution
  • Real-Life Application of Brandonite® 1000-75D
  • Estimated Replacement Savings for Three Years


Tilt Tray Sorters Reduce System Downtime by 80% for the Parcel Industry

A large parcel company is faced with the question of what to do with their nearly 20-years-old tilt tray sorter system that was becoming increasingly difficult to maintain. As with many aging systems, the acquisition of replacement parts was becoming more expensive and more difficult to secure.

With over 100 tilt tray sorter systems in operation at 20+ large sites, completely replacing each system would cost close to $7 million and over six months to implement. Globe Composite was able to develop a component to fit in the existing system’s metal track and work interchangeably, saving our client $125 million when compared to a complete system overhaul.

In this case study you will find the following:

  • Our Process: How We Went from Problem to Solution
  • Benefits & Results





  • Raytheon | Southwest | American Airlines | GE | DELTA
  • NAVSEA | US NAVY | LOCKHEED MARTIN | Huntington Ingalls Newport News Shipbuilding | Sandia National Laboratories