Guide to Conveyor Systems: Types, Uses, & Benefits

Various types of conveyor systems are essential in many industries, automating the movement of goods and materials efficiently and cost-effectively. From manufacturing to food processing to warehousing, these systems are widely used to enhance productivity and accuracy, reduce labor costs, and improve safety for goods and employees.

This article explores the different types of conveyor systems, their significant business benefits, how they can be tailored to your specific industry and warehouse needs, and how they integrate with automated storage and retrieval systems.

A conveyor is a mechanical handling system used to transport materials, products, or goods within a warehouse or manufacturing facility. It consists of belts, rollers, or chains that move items along a predefined path.

Many types of conveyor systems can be customized to meet a facility’s specific requirements and range from simple, manual systems to fully automated solutions.

Conveyor systems are among the most common forms of warehouse automation, and businesses across the globe utilize them to achieve the following benefits:

• Increased Efficiency: Automation through conveyor systems reduces reliance on manual labor, increases production speed, and results in higher output and lower costs.
• Improved Safety: By reducing manual material handling, conveyor systems reduce workplace injuries and the risks associated with heavy lifting.
• Space Utilization: Conveyor systems are designed to optimize space usage, including vertical space with multi-level configurations.
• Cost Savings: Conveyor systems reduce labor costs, minimize product damage, and decrease material handling time, ultimately leading to a higher ROI.
• Increased Accuracy: Enhanced accuracy in product handling and delivery reduces product damage, errors, discrepancies, and customer complaints.

Conveyor systems can be either manual or automated. Manual systems depend on some human intervention to move materials, while automated systems use motors, sensors, and control systems to transport materials along a conveyor belt or a network of connected belts or rollers.

A manual conveyor system generally requires employees to experience some degree of pushing carts, carrying items, or use other manual methods to move goods. In contrast, automated types of conveyor systems are programmed to perform various tasks, such as transporting, sorting, weighing, and packaging goods.

Manual conveyor systems can be suitable for small-scale operations, but they are generally less efficient and require more labor than automated systems. Automated systems are faster and more efficient, enabling companies to reduce labor costs and boost productivity.

Both manual and automated conveyor systems have benefits and drawbacks. The choice between them depends on factors such as the type of materials being moved, the size and layout of the warehouse or operation facility, and the business’s overall goals and budget.

A conveyor system consists of several components working together to move materials efficiently. The specific components vary depending on the system, industry, and materials but typically include the following:

Conveyor Belt
The main component that moves materials from one point to another is powered by an electric motor.

Rollers
Mounted individually or in groups, facilitate and guide material movement along the conveyor belt. They support the load and allow smooth movement. Rollers can be powered or unpowered.

Pulleys
Drive and control the belt’s movement. Located at each end of the conveyor system, they guide and support the belt.

Motors
Power the belt and control its speed, typically running on electric power. Some motors use variable frequency drives for precise control, while others have multiple motors for flexibility.

Idlers
Support the belt’s weight and payload, reduce friction, prevent excessive wear, and ensure proper belt tracking.

Sensors
Detect and monitor object movement on the belt, providing real-time information on position, speed, and orientation for precise control and automation.

Control systems
Oversee the conveyor system’s operations, including speed, direction, and stops. They consist of a central control panel, programmable logic controllers (PLCs), and software.

Chains
Transfer materials along the system. Made of metal or plastic links, they move smoothly around sprockets or pulleys and come in various sizes and configurations.

Conveyor systems can be tailored to meet the specific needs of various industries and operations. Customizations may involve adjusting the conveyor’s width, length, and height and controlling the belt’s speed and direction. Depending on the application, different belts, rollers, bearings, and motors can be chosen, and sensors can be integrated to enhance efficiency and safety. These modifications enable businesses to optimize their operations.

Conveyor systems can be used to connect a wide variety of material-handling equipment to create semi-automated or fully automated production or distribution lines. This process involves ensuring compatibility between hardware and software components, as well as designing the system to efficiently handle the required load and throughput. Examples of integrable equipment include automated storage and retrieval systems, sorters, palletizers, stackers, and robotic arms.

Conveyor systems vary widely, each with unique features and advantages suitable for different applications:

• Belt Conveyors: The most common type features a continuous belt moving over pulleys. They are used extensively in manufacturing and warehouses to transport goods.
• Roller Conveyors: Utilize rollers mounted on axles to move materials, which are ideal for heavy items like pallets, drums, and bulk containers.
• Screw Conveyors: Designed for bulk materials such as grains, powders, and chemicals, using a rotating spiral screw within a tube.
• Pneumatic Conveyors: Use air pressure to move fine powders like cement, flour, and sugar through a system.
• Chain Conveyors: Chain conveyors transport materials, often used in automotive manufacturing and for heavy items.
• Bucket Conveyors: Buckets transport bulk materials, which are common in agriculture and mining vertically.
• Overhead Conveyors: Feature a track-mounted system to transport materials overhead, frequently used in automotive and manufacturing facilities.

When implementing a conveyor system, consider the following factors to ensure success:

Develop Evaluation Criteria Based on the Business Case:

• Performance: Evaluate throughput, reactivity, storage density, and order accuracy to ensure the conveyor system meets your operational demands.
• Adaptability: Consider the scalability and flexibility of the system to adapt to future changes and expansions.
• Compatibility: Ensure the system meets your warehouse’s safety and ergonomics standards, energy efficiency, and security requirements.
• Reliability: Assess system uptime, performance metrics, troubleshooting responsiveness, and transparency in operations.
• ROI: Calculate implementation time, operational impact, ramp-up time, labor utilization, transportation savings, packaging savings, and new opportunities for growth.

Assessing Warehouse Needs: Understanding the unique requirements of the warehouse is the first step in choosing the right conveyor system. Factors such as the type of goods handled, volume of orders, and peak demand periods should be considered. A thorough needs assessment helps identify the tasks that can be automated and the potential benefits of implementing a conveyor system.

Evaluating System Capabilities: Different conveyor systems offer varying capabilities. Businesses should evaluate the features and functionalities of available systems to determine which ones align with their needs. For example, some systems are better suited for high-density storage, while others excel in handling diverse product types.

Considering Integration and Scalability: The chosen conveyor system should integrate seamlessly with existing warehouse infrastructure and warehouse management systems (WMS). Additionally, scalability is crucial. As businesses grow, the conveyor system should expand and adapt to increased demands without significant disruptions. The Exotec® Skypod® system exemplifies this adaptability with its modular design, allowing for easy expansion and customization based on changing needs. 

Conveyor systems pose safety risks like entanglement, pinch points, and falling objects. Essential safety measures include:

• Emergency Stop Mechanisms: Install emergency stop buttons or pull cords along the conveyor system for quick shutdowns in emergencies.
• Guards and Barriers: Install guards around moving parts to prevent accidental contact.
• Training and Safety Equipment: Provide comprehensive training and safety gear, such as hard hats, safety glasses, and gloves.
• Regular Inspections: Regularly inspect and maintain the conveyor system to ensure proper working conditions and functioning safety features.
• Warning Signs: Display clear warning signs and labels to alert workers to potential hazards and safety procedures.

While conveyors offer numerous benefits for improving manufacturing and distribution operations, they have drawbacks. The primary disadvantage is their relative immobility once implemented, making it challenging to reconfigure or relocate them as operational needs change. They require a large amount of space, which can constrain smaller facilities. Additionally, if a conveyor system breaks down, it can cause significant disruptions to operations, as the entire line may be affected until repairs are made.

For operations needing more flexibility, mobile robots like AGVs and AMRs offer viable alternatives for moving goods. For a step up in throughput and storage density, an Automated Storage and Retrieval System (ASRS) such as the Exotec Skypod system provides a highly efficient solution. 

The decision between focusing on conveyors and alternative solutions should balance the warehouse’s specific requirements, considering stability, flexibility, and operational efficiency.

The Exotec Skypod system represents a leap forward in warehouse automation, seamlessly integrating advanced goods-to-person robotics with Skypath^®, a plug-and-play automated conveyor solution that consists of straight, curved, and inclined building blocks that cover most clients’ conveyance needs.

The Skypod system serves as the core of order fulfillment operations, using advanced robotics to automate inventory storage and retrieval. Meanwhile, the Skypath conveyors integrate inbound and outbound operations, creating a seamless and streamlined order fulfillment process.

This powerful combination reduces manual handling, minimizes errors, and significantly reduces processing times. Our conveyors are engineered to be robust and reliable, offering consistent performance even in high-throughput environments.

The Skypath automated conveyor system revolutionizes bin and tote conveying, seamlessly integrating with the Skypod system to deliver unparalleled flexibility and efficiency. This plug-and-play solution features modular building blocks, including straight, curved, and inclined sections, allowing for rapid assembly to meet diverse logistical needs. Key benefits of Skypath include:

Quick to Install
Skypath’s controls are entirely API-based, eliminating the need for on-site controller programming. Combined with pre-wired components, this feature ensures a hassle-free installation process, drastically reducing the time and resources required for deployment. Up to 500 meters (1,640 feet) of conveyor can be installed in less than 200 hours, ensuring minimal disruption to your operations.

Scales to Customer Needs
Skypath’s modular design includes straight, curved, and inclined building blocks, making it adaptable to various warehouse layouts and logistic requirements. This flexibility allows the system to be quickly installed and easily modified, ensuring it can meet rapidly changing customer needs and operational demands.

Highly Efficient
With the capability to handle up to 2,700 bins per hour and speeds of up to 72 meters per minute (236 feet per minute), Skypath conveyors deliver exceptional efficiency. This high throughput ensures your warehouse operations can keep pace with demand, always maintaining optimal performance.

Performance Guaranteed
Powered by advanced software and precise engineering, Skypath conveyors guarantee reliable performance. Built-in sensors and 24/7/365 support enable swift diagnostics and remote intervention, minimizing downtime.

By integrating Skypath into your warehouse, you can achieve a highly efficient, scalable, and reliable material handling system that grows with your business and adapts to its evolving needs.

Conveyor systems are essential in various industries, automating the movement of goods with efficiency and cost-effectiveness. They enhance productivity, accuracy, safety, and space utilization while reducing labor costs.

The Exotec Skypod system, combined with Skypath conveyors, represents the future of warehouse automation. This powerful combination integrates advanced robotics with a modular, plug-and-play conveyor solution, reducing manual handling, minimizing errors, and significantly cutting processing times.

Discover more about the Skypod system and Skypath by taking our virtual warehouse tour.

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