Guide to Selecting the Right Warehouse Conveyor System

Many industries depend on conveyors and conveyor systems to transport products, from bulk materials to cartons and pallets. These systems are essential to warehouse automation and play a key role in various advanced supply chain operations. In this blog, we will cover the fundamental types of conveyor systems and examine their use in warehouse automation.

The five main types of conveyor systems found in warehouses are:

• Transportation Conveyors
• Sortation Conveyors
• Accumulation Conveyors
• Pallet Conveyors
• Gravity Conveyors

Transportation Conveyors

These conveyors perform the essential material handling function of moving products quickly and efficiently within a facility. Transportation conveyors are highly customizable and can accommodate a wide range of product sizes and weights. You can design your transportation conveyor using one of these four system types:

• Belt – A belt conveyor is a mechanical system with a continuous belt made from materials like rubber, fabric, or metal, looped around pulleys or drums. It transports bulk materials, packages, or objects horizontally or at a slight incline. Powered by one or more motors and pulleys, it’s ideal for moving boxes, cartons, odd-shaped items, and soft goods.
• Live Roller – This system consists of a series of rollers powered by a motor that drives a continuous belt or chain attached to the rollers. It works best for large, bulky, or heavy items that need sorting, queuing, or stopping during transport.
• Motor Driven Roller – Separate zones with powered rollers allow products to stop or start, with other rollers connected by belts or chains. This system is perfect for light to medium-duty applications and uses energy-efficient low-voltage power systems.
• Line Shaft – A single power shaft runs the length of the conveyor, driving the rollers using bands or belts. It can swivel to change direction and is simple to design and operate, making it ideal for moving cartons, boxes, or totes over long distances.

Sortation Conveyors

Sortation conveyors are commonly used in picking, packing, manufacturing, receiving, and shipping operations. They efficiently direct boxes, cartons, parts, or assemblies to different locations. Powered by sensors, software, and mechanical sorting devices, these conveyors can route products to specific destinations. The key difference between them lies in the sorting technology used.

• Right-Angle Transfer – These conveyors use pop-up wheels, bands, or rotating balls to change the direction of all or selected products based on input from sensors and control software. Ideal for low- to medium-rate throughput, they are integrated into transportation conveyors.
• Swing-Arm Divert – A mechanical arm sweeps across the conveyor, pushing a box or carton onto a secondary line set at an angle. Sensors and software control which items are diverted.
• Pop-Up Wheel Divert – Sensors detect when a carton needs to be rerouted to an angled secondary conveyor, activating angled pop-up wheels to change its direction. This system is cost-effective for medium-speed sorting.
• Slat or Shoe Sorter – Mechanical shoes slide across a metal or plastic slat conveyor to direct products or cartons to a secondary conveyor. It is ideal for high-speed sorting of items with varying sizes, shapes, and weights.
• Tray Sorter – Products are placed on trays that move at high speeds. Different technologies can be used for sorting: tilt trays to drop boxes onto chutes, push bars to move items onto a secondary conveyor, or split trays to release products onto a lower-level conveyor or chute for packing.

Accumulation Conveyors

These conveyors can temporarily hold products on a conveying line, making it easier to load or label boxes, create batches, or handle slowdowns further along the line. There are two main styles of accumulation conveyor designs:

• Minimum Pressure – Allows items to touch lightly, making it suitable for sturdy products in boxes, cartons, or totes.
• Zero Pressure – Uses positioning software and zones to maintain space between products, preventing contact. This design is ideal for delicate items that could be damaged if they stack up on the conveyor.

Pallet Conveyors

As the name suggests, pallet conveyors are designed to handle large, heavy loads such as loaded pallets or crates. Pallets move along heavy-duty rollers powered by chain drives. Pop-up chain drives can shift pallets at a right angle to the conveyor flow, facilitating loading, unloading, and transfer to trucks or rack systems via forklift. Pallet conveyors can also be equipped with accessories like turntables, transfer tables, and lift stations.

Gravity Conveyors

Gravity conveyors are typically used to transport items from a higher to a lower level. They can also be set up horizontally for manual push-assist movement. These conveyors can be floor-mounted or elevated to improve ergonomics. Common applications include unloading trucks or railcars, moving products to assembly or packaging lines, and staging items in shipping and receiving areas. Gravity conveyors come in two main types: straight-line frames with solid rollers or flexible frames with skate wheel rollers.

FAQ’s

What are the main types of conveyor systems used in warehouses?

There are five primary types of conveyor systems commonly found in warehouses: Transportation Conveyors, Sortation Conveyors, Accumulation Conveyors, Pallet Conveyors, and Gravity Conveyors. Each type serves specific functions and is designed to handle various tasks in the warehouse, from moving products efficiently to sorting and accumulating items for further processing.

What is a transportation conveyor, and how does it work?

A transportation conveyor is a system designed to move products quickly and efficiently within a facility. These conveyors can handle various product sizes and weights and are available in different configurations, such as belt conveyors, live roller systems, motor-driven rollers, and line shafts. They are customizable to meet the specific needs of your facility and are commonly used to transport boxes, cartons, and other materials from one point to another.

How do sortation conveyors help in warehouse operations?

Sortation conveyors are used to direct products like boxes, cartons, or parts to specific destinations during warehouse operations. Powered by sensors and software, they efficiently manage the flow of items in picking, packing, manufacturing, receiving, and shipping areas. Sortation conveyors come in various forms, such as right-angle transfers, swing-arm diverts, and tray sorters, each utilizing different technologies to route products as needed.

What’s the difference between minimum pressure and zero pressure accumulation conveyors?

Minimum pressure accumulation conveyors allow products to lightly touch while they move down the conveyor. They are ideal for sturdy items like boxes or totes. In contrast, zero pressure accumulation conveyors use positioning software to maintain space between items, preventing contact. This system is suited for fragile products that could be damaged if they come into contact with each other.

What are pallet conveyors used for?

Pallet conveyors are specifically designed to handle heavy loads like loaded pallets or crates. These conveyors use heavy-duty rollers and chain drives to move pallets efficiently. Pallet conveyors can also incorporate pop-up chain drives to move pallets at right angles for loading, unloading, or transferring to trucks or rack systems. They are commonly used in distribution centers and large warehouses.

When should gravity conveyors be used?

Gravity conveyors are typically used to move items from higher to lower levels, utilizing gravity to power the movement. They can also be set up horizontally for manual push-assist transport. Common applications include unloading trucks, moving products to assembly lines, or staging items in shipping and receiving areas. They come in two types: solid rollers for straight-line movement or skate wheel rollers for flexible, curved paths.

What are the advantages of using belt conveyors?

Belt conveyors are versatile systems that can transport a wide variety of items, from bulk materials to odd-shaped products. They are ideal for moving boxes, cartons, and soft goods over long distances. The continuous belt design allows for smooth, consistent movement, making them an essential part of many warehouse automation systems. Belt conveyors can also handle slight inclines, which makes them adaptable for various warehouse layouts.

How do motor-driven roller conveyors save energy?

Motor-driven roller conveyors feature separate zones powered by low-voltage motors. These zones only activate when needed, allowing products to stop or start without running the entire conveyor continuously. This design saves energy, making it ideal for light to medium-duty applications in facilities looking to reduce operational costs while maintaining efficiency.

Conclusion

Conveyor systems are essential for streamlining operations in warehouses and other industrial settings. By understanding the different types—transportation, sortation, accumulation, pallet, and gravity conveyors—you can design an efficient material handling process tailored to your facility’s specific needs. Whether you’re aiming to move products quickly, sort items accurately, or manage heavy loads, the right conveyor system plays a crucial role in boosting productivity and optimizing workflow in today’s fast-paced supply chain environments.