Conveyors
Conveyors are a form of material handling equipment used to transport products, packages, foods, or machinery from one point to another within a facility or through various stages of automated manufacturing or finishing. Due to the wide variety of items that conveyors are designed to move, numerous configurations exist to accommodate the specific material handling requirements of manufacturers and distributors across industries. Among these, belt conveyors are the most widely used, followed by chain conveyors, roller conveyors, spiral conveyors, conveyor systems that often integrate multiple types into a single streamlined operation.
Applications of Industrial Conveyors
Conveyors are a type of material handling equipment used to move products, packages, food items, or equipment from one location to another within a facility, or through various stages of automated manufacturing or finishing. While most conveyors are motorized, some, such as ball transfer tables and chute conveyors, operate purely through gravity. Pneumatic conveyors, though also used for material transport, function differently—they use air pressure to move bulk powdered solids through enclosed tubes. Nearly every industry that handles parts or products, particularly food processing and industrial manufacturing, relies on various types of conveyors and conveyor systems to streamline movement between workstations and stages of production.
The most common type of conveyor is the belt conveyor, which features a wide rubber or polymer belt stretched around rollers. These rollers rotate in unison to provide a consistent, linear movement that carries items along the belt’s surface. Chain conveyors are built on a similar principle but use chains instead of belts. Products may be moved on a single chain or across several parallel chains. Chain conveyors are widely used in food processing, packaging, and manufacturing to transport goods or move partially completed items through successive production phases. They are especially effective for carrying items through ovens for sintering powdered metal parts, or through parts washers for cleaning unfinished metal components.
Roller conveyors are another standard option, consisting of rows of individual rollers that rotate in place to carry objects along a path. Vertical conveyors, though less common, are critical in environments where materials must be safely lifted between levels. These systems use platforms, buckets, grippers, or magnets attached to a moving belt or chain to raise products vertically. Overhead conveyors are frequently used in parts manufacturing, where they carry parts and products across large facilities or through processes such as paint booths, dryers, or curing ovens. Complete conveyor systems often combine several types—belt, chain, roller, overhead, and vertical—to move materials across entire facilities or guide unfinished products through fully automated assembly and finishing lines.
While most conveyors rely on electric or pneumatic motors for power, gravity-driven systems are also used in certain applications. For example, some roller conveyors utilize the momentum of moving products to keep the system in motion, a principle commonly applied in downward spiral conveyors.
As industries evolve, conveyor and conveyor system manufacturers continue to develop innovative solutions to meet new challenges. Modern conveyor systems can twist, turn, climb, and descend across floors to move products efficiently and safely. Today’s systems are built to do more than just transport—they can curve, divert, lift, and sort with precision. Brushes, magnets, automated rails, levers, and even gravity are used to perform these complex tasks. In packaging facilities, systems are now programmed to identify and sort specific boxes into separate chutes. In food processing, advanced conveyors use robotic arms and sensors to handle and sort fragile fruits and vegetables with care. When paired with robotics, modern conveyor systems become highly capable tools, transforming material handling into an integrated, intelligent part of the production process.
History of Conveyors
The modern conveyor belt traces its origins to 1892, when inventor Thomas Robins developed a rotating belt system designed to assist in the extraction of ores and coal for the mining industry. Since that time, the concept of a heavy-duty conveyor system has undergone numerous revisions and innovations. These advancements have led to the introduction of new conveyor types, including the chain conveyor, overhead conveyor, and roller conveyor, along with updated versions of the traditional conveyor belt constructed from modern, corrosion-resistant materials like stainless steel.
How Conveyor Belts Work
Depending on the type of conveyor system in use, each is designed to function in a specific way. Some conveyors rely on gravity, while others require a manual push from a worker to initiate movement. Many systems, however, operate mechanically to provide automated transport.
Gravity roller conveyors consist of a series of freely rotating rollers, typically installed on a slight downward incline. This design allows rigid items like boxes to move from one point to another without the need for external power, relying solely on gravity for motion.
Overhead conveyors can operate either mechanically or manually. Their primary advantage is the conservation of floor space, achieved by suspending a system of tracks from the ceiling. Attached to these tracks are components like chains, pulleys, hooks, or other carriers, which function in the same way as ground-level conveyors but transport goods from above.
Belt conveyors and chain conveyors are usually mechanically operated. Both systems rely on a mechanical component called a V-Belt Drive, which powers the turning motion that moves the conveyor. The choice of conveyor surface depends on the nature of the items being handled. Chain conveyors feature a metal, mesh-like surface resembling a chain-link fence, while belt conveyors use a smooth, flexible belt—often made of rubber—to provide a continuous, even surface for transporting items.
Conveyor Design and Customization
Deciding which conveyor system is most suitable for a specific operation is not always a simple decision. It’s often best to carefully evaluate the details of the process, including the intended location of the system, how frequently it will be used, the destinations of the materials being moved, any physical obstacles in the area, anticipated maintenance needs due to wear and tear, and—most importantly—what type of product the conveyor will be handling.
One of the key advantages of the classic conveyor belt lies in its simplicity. With a flat, continuous surface, it smoothly moves items from one point to another, either to the end of the belt or onto a connected system. This design is particularly effective for transporting small to medium-sized items, including boxes and bulk materials. When weight and size are factored in, the belt conveyor often proves to be a flexible and efficient choice for a variety of operations.
However, it’s essential to consider the product’s impact on the belt itself. If the item is sharp, sticky, or coated in oil, it may compromise the belt’s performance or lifespan. In such cases, another conveyor system may be more appropriate for handling those specific materials.
Benefits of Using Conveyors
Chain conveyors are commonly used in food production environments. For instance, a chain conveyor made with non-stick stainless steel can be employed in donut production, smoothly guiding dough and finished products through multiple stages of cooking and flavoring. The non-stick surface reduces the risk of the items adhering to the conveyor, while the open, flexible design allows for easier cleaning—an essential feature in food processing facilities.
Roller conveyor systems are especially well-suited for warehouse and shipping operations. They make it possible to move boxes of all sizes with minimal physical strain on workers. With gravity-fed roller systems, a worker simply places a box—or any item in production—onto the rollers and gives it a slight push. The low-friction rollers allow the box to glide effortlessly across the floor, seemingly weightless. For even greater convenience, motorized roller systems offer the same functionality with added automation, using mechanisms like a V-Belt Drive to power the rollers and maintain a steady, consistent pace.
Overhead conveyors are among the most adaptable conveyor systems available. In warehouses or workshops with structurally sound ceilings or beams, these systems can transport anything from lightweight components to extremely heavy items such as engine blocks. Instead of lifting items onto a floor-level conveyor, overhead systems use pulleys, levers, chains, and other lifting tools to suspend and position products. Once secured onto a hook, platform, or chain, items are either pushed manually or moved mechanically along a ceiling-mounted track system.
One of the major advantages of overhead conveyors is the way they free up valuable floor space, creating an uninterrupted path for materials to travel from one end of a facility to the other without interfering with ground-level operations. These systems offer a balance of efficiency and simplicity, making them especially useful in multi-level operations. Rather than installing bulky floor-based conveyors between stories, a streamlined overhead system can handle vertical and horizontal transport with ease. Maintenance is minimal—keeping the tracks clean, properly lubricated, and inspected on a regular schedule is all that’s required to ensure safe, long-lasting performance.
Conveyor Installation
Conveyor manufacturers often employ skilled technicians who are fully qualified to install a wide range of conveyor systems. However, it can be helpful to understand the basic steps involved in the implementation of such systems. Despite their different functions, most conveyors follow a similar installation process. Ground-level conveyor systems (excluding overhead models) are typically installed after an area has been designated for them. Depending on floor space and access requirements, the overall layout of the facility may be altered or arranged around the conveyor system. The height is adjusted to align with connected workstations, and the direction of movement is based on the desired flow of materials—specifically, where the finished product needs to go. Each conveyor must be optimized for the handling needs of the items it is intended to move.
Once the location and direction are set, the system’s base is anchored in place. Tracks are installed to support the conveyor’s internal components, including gears, pulleys, cogs, belts, chains, and any other elements essential to its operation. For mechanical conveyors, this step is followed by the installation of the motor, belt drive, power supply, and weight distribution systems, depending on the specific type of conveyor being implemented. Each of these components is carefully checked to ensure proper performance.
In gravity-based systems, such as free-spinning roller conveyors, the rollers are inserted into pre-designed slots and grooves within the tracks. These rollers are then locked into position while maintaining their ability to rotate freely for smooth product movement.
The installation process for overhead conveyors follows a similar pattern, with one key difference: their placement is limited by the structural integrity of the building. The rail path must be planned based on the support available from ceilings or beams. Unlike ground conveyors, overhead systems must be able to safely hang from existing infrastructure, and these limitations become more critical when handling heavy objects. Once the rail path is secured, components such as chains, belts, pulleys, hanging carriers, and motors (for powered models) are attached and tested.
The final step is testing the system. Products are placed on or attached to the conveyor as they would be in actual operation, and the entire system is given a trial run. Most conveyor setups can be linked together, redirected, or adjusted to handle elevation changes. Some systems are more adaptable than others, so discussing your specific operational needs with the manufacturer or installer is essential. The ultimate goal of a conveyor system is to increase efficiency, so the features most relevant to your process should be clearly prioritized during the selection and installation process.
Conveyor Safety Considerations
Safety is a fundamental requirement in any professional operation, and it must be a top priority when working with conveyor equipment. Every potential hazard should be considered. Could the setup create risks for workers? Is there a chance the system, if mishandled, could damage products? Are there indirect dangers introduced simply by installing a conveyor system? If the answer to any of these questions is “yes,” those risks need to be carefully assessed and addressed.
Overhead conveyors, for instance, can pose hazards if not properly installed. Poor placement may result in collisions with objects or personnel, and if a load isn’t properly secured, it could fall—creating a serious safety concern. Even conventional ground conveyors present dangers. They can obstruct walkways, snag loose clothing like shirts, neckties, or even hair, or lead to pinched fingers if precautions aren’t taken.
Proper safety training is essential to protect employees, employers, and the company as a whole. As the business owner or operator, you may be held liable for hazardous conditions in the workplace. That’s why the installation of conveyor systems must be overseen and inspected by professionals. These experts are trained to recognize and resolve safety issues—many of which may go unnoticed by the untrained eye. Their experience ensures that any potential problems are addressed before they can become real threats, keeping both people and property safe.
Maintaining Your Conveyor System
The importance of conveyors in industrial processes cannot be overstated. To ensure the safe, reliable, and timely movement of materials, conveyor systems must be properly maintained. Timely maintenance is essential for keeping operations running smoothly and extending the lifespan of the equipment.
Regular Inspection
It’s vital to have machine specialists regularly examine your facility’s conveyor systems for irregularities. A routine inspection schedule should be developed, complete with a comprehensive checklist that covers all key performance indicators. These routine checks help prevent small issues from escalating into major problems, ensuring that the system continues to function without disruption. Consistent inspections significantly reduce the risk of sudden downtime, which can lead to substantial financial losses.
Training of Personnel
Equally important is the proper training of your staff in the operation and maintenance of the conveyor system. When employees are knowledgeable about handling procedures and troubleshooting techniques, issues can be identified and resolved quickly. Well-informed personnel are your first line of defense against unexpected system failures.
Customized Conveyor Systems
System incompatibility is a common cause of equipment breakdown. Using conveyors that are not suited for your specific material or load capacity can result in damage and inefficiency. Investing in a customized conveyor system that aligns with your application’s unique demands can greatly reduce the risk of failure and increase overall productivity.
Have Backups Ready
Your maintenance team should keep essential spare parts on hand for quick repairs or replacements when needed. Having backup components readily available can dramatically reduce repair times and minimize production delays. Additionally, ensure that your facility is equipped with reliable power backup systems, as most modern conveyors rely on electricity to operate.
Proper Cleaning
A clean working environment is critical to maintaining the health of your conveyor systems. Dust, debris, and other contaminants can interfere with mechanical components and sensors. A dust control system and a daily cleaning checklist should be part of your operational routine to ensure that your conveyor remains free from buildup and environmental damage. Just as with maintenance, cleanliness plays a direct role in your conveyor’s performance and longevity.
Factors to Consider When Selecting a Conveyor System
Conveyors are available in a wide range of sizes and capacities, and both the machine’s throughput and the belt dimensions can be tailored to match your exact specifications. When choosing a conveyor, your primary focus should be on your operational needs. Work closely with your supplier to ensure that the system they provide is designed to meet those needs precisely.
Easy Operation
Select a conveyor system with a user-friendly control interface. Since your workers—not the engineers who built it—will be the ones operating the system, it’s important to choose a machine that features a straightforward, accessible control setup.
Advanced Design
When reviewing quotes from various conveyor suppliers, give preference to those offering the latest equipment. By doing so, you ensure that your process benefits from the most current and efficient technology available.
Safe and Reliable
A conveyor system that doesn’t fit your space or application can introduce safety risks. It’s essential to invest in a system that supports both operator safety and the secure handling of the materials being moved.
Low Maintenance
Dependability should be a key consideration. Choose a system with a proven, time-tested design that minimizes the need for frequent repairs or maintenance. This helps reduce downtime and long-term costs.
Energy Efficiency
Since most conveyor systems are electrically powered, confirm the energy efficiency rating of the model you’re considering. An energy-efficient system can lead to significant savings over time.
Modularity
Modularity is an important feature for future adaptability. A well-engineered modular system allows for easy expansion or reconfiguration as your operational needs grow or change.
System Requirements
Before finalizing your purchase, take the time to thoroughly review the system’s brochure. It’s important to understand every feature, function, and specification of the conveyor you intend to buy. In addition, ensure that your facility meets all system requirements for proper installation and performance.
Choosing the Right Conveyor Manufacturer
When selecting a manufacturer or conveyor company to purchase your new system from, it’s important to consider several key factors: cost, the company’s reputation, their commitment to meeting your specific needs, and the range of services they provide. Reading reviews can offer valuable insight into the experiences of other customers with that company. Reach out directly to the manufacturer, explain your requirements, and ask what options would best meet your operational goals. Taking the time to understand how each company operates not only helps you avoid dissatisfaction with your conveyor system but also provides useful guidance on how to successfully integrate it into your daily workflow.
Conveyor System Types
Accumulating Conveyors
Designed to gather materials at a designated point along the conveyor line, these systems are commonly used in grouping and sorting operations.
Automated Conveyor Systems
Operate without manual input, automatically performing conveying tasks to save time and reduce labor costs.
Ball Transfer Conveyors
A material handling system that enables omni-directional manual movement of items across a surface for easy transfer and positioning.
Belt Conveyors
Transport materials using a continuous belt loop. They are widely used for moving light to medium loads efficiently through a system.
Chain Conveyors
Utilize horizontal parallel chains to move heavy or bulky materials. While effective for robust loads, they may produce uneven flow, require lubrication, and can generate noise.
Chain Roller Conveyors
Feature tread rollers connected to sprockets and powered by chains to move items along the conveyor.
Conveyor Systems
Comprehensive material handling systems that move products within a facility, often integrating multiple conveyor types to suit different stages of production or processing.
Decline Conveyors
Configured to operate on a downward slope, these conveyors guide items to lower elevations.
Drag Chain Pallet Conveyors
Heavy-duty conveyors that use strong chains to drag or handle large and heavy products. They perform well under extreme temperatures or pressure and are suitable for specialized pallet configurations.
Food Conveyors
Designed specifically for the food and beverage industry, these conveyors safely move raw or prepared food items in high-volume processing environments.
Gravity Conveyors
Rely on gravity to move objects without power. Used for tasks that involve rotating, sorting, or accumulating cartons, boxes, and bags.
Incline Conveyors
Move materials upward on a sloped path, often used when elevation changes are required within a facility.
Industrial Conveyors
Fixed systems used to transport a wide range of materials—such as boxes, raw goods, equipment, or finished products—between locations or through production stages in industrial settings.
Magnetic Conveyors
Also called magnetic slide conveyors, these systems transport small items, metal parts, or chips. They are ideal for removing materials from machinery or sorting small metallic objects.
Material Handling Conveyors
Permanent systems that facilitate the transfer of raw materials, finished goods, and equipment across facility locations or through production lines.
Overhead Conveyors
Move materials above floor level, optimizing floor space and commonly used in facilities for efficient overhead transport of parts and products.
Pallet Conveyors
Use movable platforms (pallets) to carry items between stations in industrial operations, allowing for controlled movement and placement.
Reversible Conveyors
Capable of operating in both directions, providing flexibility in transporting items forward or backward along the same system.
Roller Conveyors
Use rotating cylinders (rollers) to move items. They are commonly employed in accumulation zones and where multiple conveyor lines converge into one.
Slat Conveyors
Use flat slats, made of metal or wood, mounted on chains to carry products along the conveyor route, typically for heavy or oddly shaped loads.
Spiral Conveyors
Transport materials vertically using a spiral design. They may feature belts or slats for discrete items or enclosed screws for loose bulk materials.
Vertical Conveyors
Lift or lower materials between levels. Reciprocal types return to the original point after moving items, while continuous types move items up or down without backtracking, making them useful in tight spaces.
Conveyor System Terms
Axle
A stationary shaft on which wheels and rollers are mounted within a conveyor system.
Bag Flattener
A mechanism that positions one conveyor above another, upside-down, to compress and flatten products as they pass through.
Bearing
A component that allows the conveyor shaft to rotate smoothly without contact between the shaft and the conveyor bed.
Bed
The part of the conveyor where materials to be transported are placed.
Belt
A flexible loop, typically made of rubber or similar materials, that wraps around pulleys to move items from one point to another.
Belt Scraper
A cleaning brush or blade that removes residual material clinging to the conveyor belt.
Belt Speed
A measurement of how much conveyor belt passes a given point in a set time.
Brake Motor
A motor component that automatically activates a braking mechanism when electrical power is lost.
Brake Rollers
Rollers equipped with braking functions, either pneumatic or mechanical, to regulate the speed of conveyed items.
Casters
Swiveling wheels attached to a conveyor frame, making the system mobile.
Ceiling Hangers
Suspension rods used to hang conveyors from the ceiling, freeing up valuable floor space.
Center Drive
A centrally located drive assembly, often mounted underneath the conveyor, used in incline and reversible systems.
Cleat
A fixture attached to the conveyor belt to control or stabilize material movement.
Cleated Belt
A conveyor belt with raised sections that help retain and guide materials on inclined surfaces. These cleats may be integral to the belt or added separately.
Clutch-Brake Drive
A drive system that stops the belt instantly without cutting power, combining a clutch and brake mechanism.
Clutch Drive
Allows the motor to be disengaged from the drive system without shutting down power to the motor.
Converging
A section of conveyor where two separate lines merge into one.
Cross Bracing
Diagonal rods installed across conveyor frames to square the system and assist with belt tracking.
Drive
The complete motorized assembly responsible for powering the conveyor belt or rollers.
Drive Pulley
The pulley connected to the conveyor’s motor, responsible for moving the belt.
Feeder
A conveyor designed to control the flow rate of items being introduced into a processing or packaging system.
Flow
The directional movement of materials along the conveyor.
Frame
The structural body of the conveyor system that supports all components.
Horsepower
A unit of power that measures how quickly work is done—commonly used to describe conveyor motor strength.
Infeed End
The loading end of the conveyor where materials are first placed.
Intermediate Bed
The middle portion of a conveyor, located between the drive and tail ends.
Lacing
A method for joining two ends of a conveyor belt together.
Magnetic Starter
An electrical control device that starts the motor and includes overload protection.
Motor
Converts electrical energy into mechanical energy to power the conveyor system.
Nose Roller
A small roller at the end of a curved conveyor used to minimize the gap during product transfer.
Overhead Drive
A drive unit mounted above the conveyor to allow unobstructed space beneath for larger products.
Plow
An angled device placed across a conveyor to divert or remove items from the main path.
Pop-Out Roller
A roller set in a shallow groove that can eject outward if a blockage occurs, helping prevent damage or injury.
Powered Feeder
A powered segment at the beginning of a conveyor, used to load items horizontally onto an incline conveyor.
Pressure Roller
Used in belt-driven roller conveyors to press the belt against the carrying rollers, ensuring contact for driving the load.
Pulley
A wheel with a grooved rim that guides and powers the conveyor belt via rotation.
Pusher
A mechanical arm or mechanism used to shift items from one conveyor line to another or into a chute.
Roller
A cylindrical component that rotates to support and move materials along a conveyor; available in various profiles like straight, tapered, or crowned.
Roller Bed
An arrangement of rollers that form the supporting surface for the materials being conveyed.
Shaft
A rotating bar that transfers torque to support and move materials on the conveyor.
Slider Bed
The smooth base over which a belt conveyor glides, offering consistent support and direction.
Slug Mode
A release mode in which all queued packages on a conveyor are released simultaneously.
Throughput
The volume of material moved through a conveyor system in a specific period of time.
Tracking
The process of adjusting a conveyor belt’s alignment to ensure it stays centered on the system.
Transfer
A mechanism used to redirect products between adjacent or intersecting conveyor lines.
Turnbuckle
An adjustable link with threaded ends used for tightening rods, commonly found in cross-bracing.
Turning Wheel
A component that assists in correctly orienting products as they move along a conveyor.
