The Ultimate Guide to Conveyor Systems
Are you looking for information about Conveyor Systems and their role in e-commerce, warehousing, and logistics? In this guide, we provide an overview of everything you need to know about conveyors—from what they are and how they work, to their pros and cons, different types, and control systems, as well as practical tips on how to optimize your warehouse with the right conveyor solution.
Conveyors play a crucial role in warehouse and logistics operations by streamlining material handling and automating the movement of goods between different areas of the warehouse—from goods receiving to storage, picking stations, packing, and finally shipping.
The use of conveyors reduces manual handling and speeds up internal processes, leading to higher productivity, lower costs, and improved working conditions for employees.
What is a conveyor?
Conveyors, also known as Conveyor Systems, are systems used to move goods and materials within a warehouse, for example. There are primarily two types of conveyors used in the warehousing and logistics sector: Belt conveyors and roller conveyors. These systems have their own advantages and disadvantages depending on the application and specific needs.
Why are carriers important?
Increased efficiency
Automated material handling: Conveyors enable the continuous and automated movement of goods, eliminating the need for manual transport. This reduces lead times and improves the flow of materials through the warehouse and logistics process.
Faster order processing: By integrating conveyors into picking and packing processes, goods can be transported quickly and efficiently between different stations, resulting in faster delivery times and more satisfied customers.
Reduced manual handling: Using conveyors to move heavy or bulky goods reduces the physical strain on staff, leading to fewer injuries and a better work environment. Staff can instead focus on tasks that add more value.
Belt conveyors
Belt conveyors use a belt, often made of PVC, to transport various types of goods. They are used in many industries and can be adapted for different types of materials and environments.
Advantages of belt conveyors versus roller conveyors
Versatility: Can handle small, fragile, uneven, or irregularly shaped items that are not suitable for roller conveyors.
Smooth and stable transport: The continuous belt provides a stable surface that reduces the risk of products shifting or falling off during transport.
Ability to handle slopes: Can be designed to handle both uphill and downhill slopes.
Lower noise level: Tends to be quieter than roller conveyors.
Adaptation to different environments: Can be used in wet, dusty, or chemically aggressive environments.
Disadvantages of Belt conveyors versus roller conveyors
Energy consumption: Requires a constant supply of energy.
Limited weight capacity: Less suitable for very heavy cargo.
More susceptible to potential stoppages: If the belt breaks for any reason, the entire machine stops, and material flow along that section comes to a halt. For this reason, a belt conveyor is more susceptible to stoppages than a roller conveyor, since the rest of a roller conveyor often continues to operate even if a single roller stops.
Roller conveyors
Roller conveyors consist of a series of rotating rollers and require that the items being transported have a flat bottom in order to be transported efficiently. They are often made of steel, aluminum, or plastic, depending on the application and the specific requirements for durability, load capacity, and corrosion resistance.
Roller conveyors can be customized in length, width, and height to suit various production environments and transport needs, making them a flexible solution for many types of material handling.
Different types of roller conveyors
Gravity conveyors: It does not use an external power source and is tilted so that objects move by means of gravity.
Motorized/powered roller conveyors: Powered by a motor, it can transport objects along horizontal or inclined paths.
Chain-driven roller conveyors: Used for heavy loads and driven by chains that connect the rollers.
Advantages of roller conveyors versus conveyor belts:
Cost-effectiveness: Lower initial and maintenance costs.
Simplicity and reliability: Sturdy construction and easy to customize.
High maximum load: Suitable for heavy and bulky items.
Disadvantages of roller conveyors versus conveyor belts:
Limitations in material handling: The cargo to be transported requires a flat surface to ensure optimal transport.
Less control over transportation: No speed limits on gravity tracks.
Limited ability to handle slopes: It is more difficult to manage differences in floor levels without custom solutions.
Property | Conveyor belts | Roller conveyors |
|---|---|---|
Versatility | Can handle uneven, | Requires items with a flat bottom |
Maintenance | Higher maintenance requirements | Lower maintenance costs |
Energy consumption | High energy consumption | Lower energy consumption |
Handling of heavy cargo | Limited capacity | Great for heavy and bulky items |
Control system for conveyors
Modern conveyors use advanced control systems to improve the efficiency, safety, and flexibility of material handling. Below, we review common components related to control systems in Conveyor Systems.
PLC (Programmable Logic Controller): Controls and automates Conveyor Systems by processing signals from sensors and sending commands to motors and other components.
Sensors: Includes proximity sensors, photoelectric sensors, optical sensors, and load cells. These are used to detect objects, position, speed, and weight.
Example: Optical sensors can detect when an object passes a certain point.
HMI (Human-Machine Interface): Enables interaction between operators and control systems, provides real-time data, and allows for parameter adjustments.
Benefits of HMI: Improved control and faster problem resolution.
Image of the HMI below:
Return on Investment (ROI) of Conveyor Systems
A study by the Aberdeen Group found that companies that implemented automated Conveyor Systems saw an average 20% increase in operational efficiency and a reduction in labor costs of up to 15%. In addition, 75% of these companies reported a full return on investment within 12–18 months of installation. For used systems, ROI can be achieved even faster.
Summary
Conveyors are a key component of modern warehouse and logistics systems. The choice between belt conveyors and roller conveyors depends on specific needs, such as the type of goods, the environment, and cost requirements. To maximize efficiency, we recommend that you carefully weigh the pros and cons of each type of conveyor and invest in a customized control system to optimize the flow. Not sure what’s right for you?
Contact us today!
At Relevator, we have both belt conveyors and roller conveyors—both non-powered and powered—available for immediate delivery. Contact us Today, we’ll help you find the carrier that best suits your specific needs!
