Guide: Optimizing Warehouse Flow with Roller Conveyors

Do you want to shorten lead times, reduce manual labor, and save money at the same time? With the right roller conveyor in the right place, you can transform a chaotic warehouse workflow into an efficient system where goods move quickly and smoothly.
In this guide, we’ll show you how companies have improved their logistics using roller conveyors, and why used roller conveyors often offer the greatest return on investment.

Roller conveyors play a central role in modern logistics environments. By installing the right roller conveyor in your warehouse, you can reduce costs, improve the work environment, and create a faster and more reliable flow of goods.

1. Roller conveyor for more efficient warehouse flow

Analyze the current situation

Start by reviewing how goods are currently moved. Where do delays occur? Which steps are performed manually? Identifying bottlenecks is crucial to determining where a roller conveyor can have the greatest impact on the warehouse.

Strategic location

Place roller conveyors where the flow is most intense, such as between picking, packing, and loading. Proper placement creates a natural flow of goods and reduces the need for manual steps.

Research funding: A study Research from Mälardalen University shows that optimizing warehouse layout and material flow can lead to significant efficiency gains. By restructuring the warehouse with a focus on flow optimization, the company in the study reduced unnecessary activity and also improved the flow of goods. Among other things, an ABC analysis was conducted on 203 items, where 65% were classified as low-frequency C-items and could be relocated to a new warehouse, which freed up space and simplified the handling of the most frequently used goods. This is something that is further enhanced by automated solutions such as roller conveyors.

2. Before and After: How the roller conveyor improves daily operations in the warehouse

Before: manual labor and slow production flows

A company that distributes beauty and hair care products previously used a manual system to receive and sort incoming shipments. Three people were needed to unload pallets, check the goods, transport them by forklift, and place them in the correct area of the warehouse. Because all the work areas were spread out, there were many steps involved, with long distances between them.

Next: Smarter flow with roller conveyors

By installing a roller conveyor from the receiving area to the picking station, an automated and streamlined workflow was created in the warehouse. Goods are now scanned immediately upon arrival and then move on to their designated locations without anyone having to manually carry, drive, or lift them. Ultimately, this means that a single person can manage the entire process on their own.

“Time and again, we see how a simple roller conveyor can transform the entire logistics flow. For many of our customers, it has been a crucial piece of the puzzle that has enabled them to grow without hiring more staff or expanding their warehouse.”
- Jacob Sardal, Business Developer at Relevator

3. A safer work environment with roller conveyors

Manual handling of goods takes a toll on the body. Everything from heavy lifting and repetitive movements to poor posture increases the risk of repetitive strain injuries. Roller conveyors can help avoid all of this, which helps reduce the risk of back and shoulder problems, as well as sick leave.

In other words, a well-designed roller conveyor isn’t just a measure to improve efficiency—it’s an investment in employee health!

4. Technology and innovations in conveyor systems

Powered roller conveyors

Powered roller conveyors can transport everything from light packages to heavy cargo without any manual handling. They can also adjust their speed and direction in real time as needed.

Integration with autonomous mobile robots (AMR)

Autonomous robots integrated with conveyor systems enable goods to be moved smoothly between different zones of a warehouse without requiring staff to perform manual tasks during the process.

5. The Cost-Effectiveness of Choosing the Right Roller Conveyor

Comparison: new roller conveyor vs. used roller conveyor from Relevator

Aspect	New roller conveyor	Used roller conveyor from Relevator
Price	Significantly more expensive than buying used	On average, 60–70% lower than buying new
Installation time	May require longer lead times; delivery times of 6–12 weeks are not uncommon	In stock, fast shipping
Environmental impact	New materials and manufacturing	Circular alternative, reduced carbon footprint

Long-term savings

A carefully selected roller conveyor system can reduce staffing needs, increase the flow of goods, and lower costs associated with injuries and sick leave, resulting in a quick return on investment.

“It’s not just about selling a roller conveyor; it’s about understanding the workflow, finding the right solution, and installing it in a way that delivers immediate results. With the right planning, we often see that customers can free up both time and space as early as the first week.”
- Jacob Sardal, Business Developer at Relevator

6. The Future of Roller Conveyors in Warehouse Automation

Integration with the entire warehouse management system

Today, a roller conveyor can be integrated with WMS, robots, scanners, and other warehouse automation which creates efficient workflows throughout the warehouse.

Here’s how Relevator can help you find the right roller conveyor

At Relevator, we have extensive experience helping companies find the right solution for their unique needs. We offer:

- Needs Assessment and Consulting
- Used roller conveyors
- Reliable delivery and installation