How M.R. Snyder Transformed a Dental Supply Manufacturer’s Warehouse Automation

When operational efficiency is the difference between staying competitive or falling behind, having the right automation partner is critical. At M.R. Snyder Company, we specialize in system retrofits as well as warehouse and packaging automation integration, delivering cutting-edge solutions that not only fix what’s broken—but prepare your facility for the future.

A recent partnership with a large dental supply manufacturer is a prime example of how we help companies upgrade from outdated systems to reliable, intelligent automation platforms designed for uptime, flexibility, and growth.

The Challenge: Obsolete Controls, Frequent Downtime, and a Fragile Conveyor System

The manufacturer’s multiple facilities were struggling with aging infrastructure:

• Outdated & low-end PLCs & Windows based HMI System
• Obsolete barcode scanners
• Poor support from their previous integrator
• Minimal on-site technical expertise
• Slow recovery from breakdowns due to lack of diagnostic tools
• A series-based Ethernet MDR conveyor system where a single roller failure would halt the entire plant

Frequent downtime, poor throughput, and limited troubleshooting capabilities created a bottleneck in their daily operations. When one node in their conveyor system went down, the entire system would come to a stop—crippling production until the issue could be manually traced and resolved.

The M.R. Snyder Solution: Intelligent Upgrades & Future-Proof Design

Our team engineered a complete automation overhaul to transform the client’s multi plant control system into a modern, efficient, and resilient operation. Here’s how we delivered:

• Replaced Outdated PLCs & HMIs

We upgraded the facility’s outdated Automation Direct PLCs with new state-of-the-art control systems, providing a more stable, scalable, and industry-supported platform for future growth and automation expansions.

• Installed advanced barcode scanners and diagnostics

We installed modern, high-speed barcode scanners and controls equipped with advanced diagnostic capabilities. This gave the operations team real-time visibility into issues, drastically reducing downtime and guesswork.

• Implemented E-Stop Diagnostics with Location Tracking

We added advanced E-Stop diagnostics that display the exact location of a pulled E-Stop or safety device, eliminating the need to manually check every station. Now, operators can immediately identify and resolve safety interruptions.

• Redesigned MDR Conveyor Network for resilience

We completely restructured their conveyor control system, replacing the fragile series-based Ethernet configuration with a robust star network topology. This change gave independent control over each conveyor section—so if one node goes down, the rest of the system keeps running. This upgrade alone turned a vulnerable setup into a resilient operation capable of withstanding isolated failures without stopping the entire line.

• Remote support & future scalability

To top it off, we enabled remote connectivity to their PLCs, allowing M.R. Snyder to remotely support, troubleshoot, or upgrade the system without delay – reducing response time and keeping operations flowing, even when on-site resources are limited.

The Results: Efficiency, Visibility, and Peace of Mind

With the new system in place, the manufacturer now benefits from:

• Significantly reduced downtime
• Improved throughput and system reliability
• Faster issue resolution with location-specific diagnostics
• A scalable automation platform ready for future growth
• Ongoing expert support from the M.R. Snyder team

Why Choose M.R. Snyder?

At M.R. Snyder Company, we do more than just upgrade hardware – we design and integrate automation systems that solve problems, optimize performance, and empower your team with the tools and information they need to succeed.

If your warehouse or packaging line is being held back by aging controls or limited system flexibility, we’re ready to help you transform it. With our industry expertise, cutting-edge solutions, and commitment to support, M.R. Snyder is your trusted partner in warehouse automation. Let’s build the future of your facility—together. Contact us today.