Sure, maybe if you’re 10,000 or so cases of inventory per shift, then you might want to slap the cash on the barrelhead.

Otherwise, you can get by with far less.

By adding something as simple as a basic layer of automation — such as an oval conveyor belt — you can reduce the required head count for getting product from the shelves to the shipping area. The whole concept pays for itself in about 30 months, experts say.

There’s still a manual sorting system, fed by by the re-looping conveyor belt with access to picking areas. The key is batch picking, which saves time and money as trips are logically consolidated.

The consolidated cartons are put on a conveyor belt, which feeds into the looping system. Then, as the cartons slowly chug by the packing area, workers pull what’s necessary for each order. They build each order — manually — then label and stack the packages on nearby pallets. From there, the packages easily pass through the loading area and out of the building.

If packers miss an item or two, the product will be re-circulating shortly and the packer can pull what’s needed without leaving his or her spot. Everything’s at his or her fingertips, without making additional picking trips.

Experts say a system like this save can quickly pay for itself, as it will free the time four to six workers would otherwise rack up in labor costs. Those workers can be deployed in other areas.

The return on investment can be accelerated, by increasing the workload of the packing process. Such growth can occur without requiring any additional expenses.

Why isn’t this approach finding more favor?

Consultants and system sellers have a vested interest in selling you the biggest package possible. Hardware providers prefer larger projects, which lead to larger profits.