Comprehensive conveyor systems guide: Boosting efficiency and safety
Conveyor systems provide controlled material flow through manufacturing plants, warehouses and distribution centres, reducing reliance on manual handling. This guide explains how conveyor systems work, the main types, where they are used and what to consider when choosing one.
What is a conveyor system?
A conveyor system is a mechanical handling system that moves materials or products from one point to another within a facility. It uses frames combined with belts, rollers, chains, air or overhead tracks, driven by motors or by gravity, to carry loads between stages of production, storage or distribution.
Types of conveyor systems
The right type depends on what is being moved, how far, how fast and in what environment. These are the most common conveyor types:
Belt conveyors
Belt conveyors use a continuous belt, made from materials such as rubber, PVC or fabric, to carry products of different shapes and sizes. They can be designed with inclines and curves to suit complex layouts and are widely used in food processing, manufacturing and mining.
Roller conveyors
Roller conveyors move items along a series of rollers, either powered or using gravity. They suit cartons, totes and heavier unit loads, and their modular construction can allow systems to be extended or reconfigured as requirements change. Typical applications include warehousing, logistics, packaging and automotive assembly.
Chain conveyors
Chain conveyors use chains driven by sprockets to move pallets, containers and large industrial parts. They are built for heavy loads and harsh environments, making them suitable for automotive and other heavy manufacturing applications.
Pneumatic conveyors
Pneumatic conveyors use air pressure or vacuum to move bulk materials such as powders and granules through enclosed pipes. Their enclosed design suits pharmaceutical, food and chemical processing, and they can be configured for dense or dilute phase conveying.
Overhead conveyors
Overhead conveyors carry items on an overhead track, keeping the floor clear for other operations. They can move loads between levels and around obstacles. Typical applications include automotive assembly lines and paint shops.
The main differences at a glance:
| Conveyor type | How it moves loads | Typical uses |
|---|---|---|
| Belt conveyor | A continuous belt driven over pulleys | Food processing, manufacturing, mining, parcels and cartons |
| Roller conveyor | Powered rollers or gravity | Cartons, totes and heavier unit loads in warehousing, packaging and assembly |
| Chain conveyor | Chains driven by sprockets | Pallets, containers and heavy parts, including automotive manufacturing |
| Pneumatic conveyor | Air pressure or vacuum through enclosed pipes | Powders and granules in pharmaceuticals, food and chemicals |
| Overhead conveyor | Carriers running on an overhead track | Automotive assembly, paint shops and lines where floor space is limited |
Where are conveyor systems used?
- Manufacturing: moving raw materials, parts and finished products between production stages, in continuous or batch processes.
- Food and beverage: transporting ingredients and packaged goods with equipment designed to meet hygiene requirements.
- Mining and heavy industry: carrying bulk materials such as coal, ores and minerals to processing plants and stockpiles.
- Warehousing and distribution: sorting, packing and dispatching goods, often as part of wider warehouse automation systems.
- Automotive: moving bodies, components and heavy assemblies along production and paint lines.
Benefits of conveyor systems
- Throughput: loads move at a consistent rate between stages, which helps production keep pace with demand.
- Safety and ergonomics: less manual handling can reduce repetitive lifting and carrying of heavy or awkward items.
- Lower handling costs: automated movement can reduce the labour needed for repetitive transport tasks.
- Flexibility: modular systems can be extended or reconfigured as production needs change.
- Space use: inclined, vertical and overhead conveyors make use of height as well as floor area.
What to consider when choosing a conveyor system
- Load and throughput: the weight, size and shape of the items being moved, and the rate the system has to achieve.
- Layout and integration: the route through the facility and how the conveyor connects to existing equipment and control systems.
- Safety features: emergency stops, guarding and sensors, designed to the safety standards that apply where the system is installed.
- Installation: site readiness, sequencing, electrical connections and testing. Our step-by-step guide to conveyor installation covers each stage in detail.
- Maintenance: routine inspection, belt and roller replacement and planned maintenance to keep the system running reliably.
- Future capacity: whether the design allows the system to be extended if volumes grow.
Beck & Pollitzer installs conveyor systems as part of its machinery installation services, from mechanical assembly and electrical connection through to testing and commissioning support.
Frequently asked questions
Chain conveyors are commonly used for pallets, containers and heavy industrial components. Roller conveyors can also handle heavier unit loads, depending on the load, spacing, support structure and system design.
A belt conveyor carries items on a continuous moving surface, which suits small, irregular or loose products. A roller conveyor moves items across a series of rollers and suits items with a firm, flat base, such as cartons, totes and pallets.
Most do. Powered conveyors use electric motors to drive belts, rollers or chains. Gravity roller conveyors need no power and rely on a slight decline to move items, which makes them useful for simple transfers and accumulation areas.
If you are planning a new conveyor system or extending an existing one and want to discuss layout, installation or integration, contact Beck & Pollitzer.