PSI Engineering is set to implement new outbound conveyor automation at Cardinal Health at-Home Solutions’ distribution centers. Serving approximately 5 million U.S. customers each year, Cardinal Health at-Home Solutions delivers essential medical supplies and equipment to patients with chronic conditions, including diabetes and incontinence.
As part of a multi-year initiative to enhance warehouse capacity and modernize operations through automation and robotics, PSI’s automated pack line conveyor system will feature in the new distribution centers in South Carolina and Ohio, and will be a key component of the Texas facility slated to open in 2025.
“Cardinal Health is leading the way in the industry by adopting the latest pack area automation technologies,” said Gary Hughes, CEO of PSI. “We’re excited to support Cardinal Health at-Home Solutions in its mission to better serve its customers.”
In the Ohio and South Carolina distribution centers, PSI’s automated conveyor spans over 750 linear feet, routing nearly 800 boxes per hour through outbound operations. Five scanners ensure package accuracy, with over seven customizable label variations based on box contents. The Grove City, Ohio, facility opened in 2023, followed by the Greenville, South Carolina, center this summer. The upcoming Texas center will feature nearly 1,500 linear feet of conveyor capable of moving 1,800 boxes per hour—nearly double the capacity of the existing centers.
This advanced conveyor technology will help Cardinal Health meet the increasing demand for at-home medical supplies, enhance outbound operational quality, and adapt to evolving transportation needs.
“Our transformation journey in the supply chain is focused on integrating the right automation and robotics to efficiently meet customer demands,” said Mike DeSimpelaere, Vice President of Network Operations at Cardinal Health at-Home Solutions. “This technology will expedite the delivery of critical medical supplies to patients, creating stronger and more efficient warehouse operations. Additionally, PSI’s scalable system will support our continued business expansion.”
PSI’s Pack Line automates the SLAM process (scan, label, apply, and manifest), streamlining the outbound processes of both facilities.
“Automation in the packing area is often overlooked, yet it plays a vital role in the order fulfillment process, where bottlenecks and errors can hinder production,” said John Pollock, PSI’s Director of Client Solutions. “Cardinal Health has adopted a comprehensive approach to their automation strategy, reflected in the solutions we’ve developed. Our lines automate ten major touchpoints, addressing all aspects of variable data handling, labeling, and sortation within the existing software infrastructure.”
PSI’s original equipment manufacturer (OEM) machinery is designed to meet the needs of Cardinal Health’s direct-to-patient distribution model, effectively scanning unique barcodes and handling related documentation. The pack line automation technology sorts packages for their respective shipping ports.
Integra, PSI’s pack line system management software, offers visibility into production metrics, inventory health, equipment efficiency, and alarm history. It integrates seamlessly with Cardinal Health at-Home Solutions’ new warehouse management system to ensure an error-free packing process. Additionally, the conveyor technology works with the distribution centers’ robotic fulfillment and on-demand packaging systems, automating nearly every step of the pick, pack, and ship process.
About PSI Engineering
PSI Engineering collaborates with clients globally to enhance facility productivity, optimize labor costs, and improve order packing efficiency. With over 30 years of experience, PSI has become a leading provider of end-to-end pack line solutions, from consultation and design to manufacturing and support. The final stages of the warehouse process are their top priority, ensuring that investments in picking and shipping do not falter due to packing bottlenecks.
About Cardinal Health
Cardinal Health is a distributor of pharmaceuticals and a global manufacturer of medical and laboratory products. With over 50 years in the industry, operations in more than 30 countries, and approximately 48,000 employees worldwide, Cardinal Health plays a crucial role in healthcare delivery.
