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Conveyor Belts Conveyor Systems

Belt Conveyor Vs Live Roller Conveyor | Conveyor Systems

Belt Conveyor vs. Live Roller Conveyor

Conveyor systems move materials from one point to another. Though there are different conveyor system designs, they all share the same general structure: a frame with wheels, rollers, or a belt. The power can come from gravity or a motor. In some cases, someone can manually push the materials using the conveyor for assistance.

The two most common types of conveyor systems are belt and roller conveyors. Both are common in warehouses and logistics facilities, where they transport and accumulate products. Both belt conveyors and roller conveyors are used for assembly, sorting, inspection, and packing.

Though they have similar functions, there are important differences between belt and roller systems. Each kind has advantages that make it best suited for specific tasks.

Differences in Appearance

There are some noticeable differences between belt conveyors and live roller conveyors.

A roller conveyor consists mainly of solid, tube-shaped rollers, which directly contact and transfer motion to the materials that they transport. These rollers may be steel or composite tubing. Some roller systems are gravity-powered, but live roller conveyors rely on a motor.

A belt conveyor, on the other hand, has a single, flat steel or composite belt for its surface. It provides stable support for the materials, and it gets its power from a drive pulley or a rotating cylindrical tube driven by a motor.

There are many subtypes for both conveyor systems. For example, roller conveyors may be belt-driven, roll-to-roll-driven, and chain-driven. On the other hand, belt conveyors can have an angled design (such as trough belts) or be completely level (flat sidewall belts). There are numerous designs, but for this article, we will focus on two of the most common: the powered belt conveyor and the live roller conveyor.

Live Roller Conveyor Definition

Live roller conveyors use steel or composite rollers that directly contact with and transmit motion to the conveyed product or material. The name “live rollers” comes from the fact that they get power from a motor (instead of gravity or manual operation). Live roller conveyors can be either belt-driven or chain-driven.

Live rollers are most common in settings that call for transporting large or heavy products, including cartons, boxes, and pallets.

Powered Belt Conveyor Definition

Belt conveyors have a steel or composite belt that sits on top of rollers or a smooth slider bed. Typically, a motor-driven cylinder underneath the belt or at the end of the conveyor powers the system. The belt comes into direct contact with the conveyed product or materials. 

This conveyor system provides a high degree of control, especially when moving materials on incline, curve, and decline. Belt conveyors are common for jobs that require moving irregularly shaped objects, small and medium boxes, and fragile objects. They are also regularly used for moving objects of all sizes up or down an incline.

When to Use a Live Roller Conveyor

Live roller conveyors are ideal for general-purpose operations where precise positioning and control are not important or when products are likely to be in continuous flow. However, it is essential to note that transfer speed will not remain constant. Instead, it will depend on the weight and volume of the materials. 

Typical applications for live roller conveyor systems include:

  • Long-distance conveyance
  • Return lines
  • Pallet transport
  • Bulk goods receiving
  • Load transfer and accumulation
  • Delivering products to and from automated manufacturing or sorting stations

When to Use a Belt Conveyor

Belt conveyor systems are most appropriate for complex situations requiring more precise control and positioning. They are especially advantageous when transporting products on a sloped surface or moving fragile or irregularly shaped objects. 

Typical applications for this type of conveyor include:

  • High-speed conveyance
  • Assembly
  • Automated manufacturing systems
  • Scanning
  • Inspection or sorting
  • Incline and decline conveyance

How to Choose the Best Conveyor for Your Needs

Choosing the right conveyor system can improve productivity and efficiency and limit the chances of damage to products. To learn more about different conveyor systems and get help with the selection process, visit our conveyor product page or contact Handling Solutions to request a quote.

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Conveyor Systems

Overhead Conveyor Systems and Design

The ideal overhead conveyor system for your facility is the one that makes the best possible use of space in your work areas, helping you increase productivity using work zones, right up the ceiling level.

Use this guide to help you identify the “must-have” features of your overhead conveyor.

Enclosed Track Conveyors

An enclosed track conveyor uses a track that closes completely around the trolley connector. Only a small gap is left to accommodate the connector that holds the trolley, hanging beneath the track. These designs are a little more sophisticated than open track configurations, and they may be more difficult to install. However, the inside of the track is protected from environmental wear and tear, and an enclosed track can incorporate bends and curves more easily where required.

Open Track Conveyors

An open track conveyor does not close around the trolley connector, and it has an ɪ-shaped cross-sectional profile similar to that of a steel girder. Installation tends to be easier and less costly than for an enclosed track conveyor. And, this type of designer may be more suitable for applications in which long, straight sections of track are necessary.

Synchronous Conveyors

If you are conveying a steady stream of items along your system, a synchronous conveyor ensures these items move in sync. In other words, items are evenly spaced along the system and move at the same rate. This is very useful on assembly lines, when the equipment needs to remain operational even at higher volumes. You will also be able to retain full control over the entire network from a centralized point.

Asynchronous Conveyors

If your conveying needs are a little more ad hoc – with different items being transferred through as and when required – an asynchronous system may be the better option. This type will not be running all the time and may not be powered at all – you will simply send items through whenever you need to. 

NOTE: Some systems may be able to run both synchronously and asynchronously to reflect the needs of businesses. If you are interested in this type of conveyor, be sure to work with an expert team. Pricing can be an issue, and only an experienced provider can help you design a combo system within budget.

Powered Conveyors

A powered conveyor is simply an overhead conveyor that drives trolleys around the network. If you need trolleys to travel long distances or to travel up gradients, you will require a powered conveyor system. The main difference between power and free conveyor is that powered systems are more sophisticated and may be more expensive to install and to maintain.

Free Conveyors

Free conveyors do not apply any additional power to move trolleys around the system. They may use gravitational energy to move trolleys from A to B, but they do not have any additional power needs. As such, they are relatively simple to install, and they have fewer operating parts that may become damaged and need repairing or replacing. Many asynchronous systems utilize free conveyors.

Find the Ideal Overhead Conveyor System for Your Needs

You need a conveyor system that is up to the task – one that is heavy-duty enough to meet your business’s load capacity needs. The above equipment types are intended as a guide, and it is likely that your own needs will be a little more unique or specialized. For example, you may need a custom solution to operate in a small space, or you may require a conveyor built for the unique configurations of a packaging room.

Reach out to our team today and let us help you identify the perfect overhead conveyor system for your material handling system.

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Conveyor Systems

EFFECTIVE SORTING CONVEYOR SYSTEMS

If you’re considering upgrading or replacing your current sorting conveyor system, now is the time. According to a recent study from Technavio, the conveyor market is expecting a compound annual growth rate of 5% over the next three years, despite the COVID-19 shutdowns. The transition to an e-commerce economy is forcing businesses to increase investments toward factory modernization; making the marketplace even more competitive.

While all sorting equipment is designed to safely, efficiently and effectively organize items traveling along a conveyor belt, the latest technology advancements are plentiful. They offer solutions for continuous material handling across product lines and industries.

To help narrow down your choices and identify the most important “big picture” features for your business, we have put together a guide to help you find the most modern sorting conveyor system that for your sector.

SORTING CONVEYOR SYSTEMS TERMINOLOGY

If you’re looking to take your warehouse conveyor to the next level, familiarize yourself with these terms, trends, and technology:

SORTATION CRITERIA

Before you begin comparing sorting conveyor systems, take a moment to identify the following criteria:

  1. Are you sorting units or cases?
  2. Does your current equipment accurately reflect inventory and where it’s located?
  3. Is broken or damaged product a problem for your business?
  4. Does your business struggle with space for workers?
  5. Are return processing and putaway slowing productivity?

Once you’ve answered those questions, review the main sortation categories to narrow down the choices that will best suit your business objectives.


UNIT VS. CASE SORTERS, SPEED, AND FORCE

SLIDING SHOE / SLAT SORTER

Shoe sorters have been the go-to choice for facilities with high volumes of products for many years, and recent technology advancements are the sorting conveyor of choice for fragile inventory. They’re not as fast as other types, but they’re a popular choice for their ability to manage a diverse range of products at a medium to high speed sortation rate. They’re ideal for sorting cases but they’re also used to sort units.

A “shoe” is a component that moves laterally across the surface of the conveyor to divert a pre-determined item from its course. The design provides quiet, gentle, and accurate sorting. Shoe sorters are known as slat sorters because slats are used to move product through the conveyor system. The diagonal motion keeps the product from being damaged. Sliding shoe sorters fall into the “linear” category of sortation systems; the design reduces equipment wear and the slat design allows for repairs to small sections rather than the entire machine.

CROSSBELT SORTER

Crossbelt sorters are a popular choice for small units that require a high rate of speed. The cross belt sorter with a loop design provides two induction areas, yielding twice the rate as a linear design. and sorting the product by diverting it into a chute. Crossbelt sorters can be used with automation stations or manual operators and offer high sorting rates, higher than the sliding shoe sorter. Crossbelt sorters are popular in e-commerce, grocery, and retail clothing operations.

Crossbelt sorters fall into the “circular” sorter category, known for high sortation rates and compact design.

TILT TRAY SORTERS

Tilt tray sorters are similar to crossbelt sorters, but they run in a continuous loop and use trays that tilt the product into chutes or another conveyor belt. They also sort units and their speed can exceed the crossbelt sorter. Tilt tray sorters are a popular choice in the pharmaceutical industry, publishing, and mail order fulfillment.

NARROW BELT SORTERS

The Narrow Belt Sorter is very similar to the crossbelt sorter, but it exerts less force on sorted items. Narrow belt sorters are a popular choice in the auto parts industry, electronics, and food and beverage. These sorters can move product at a 90 degree angle without damage. Like sliding shoe sorters, narrow belt sorters can move cases or units. Narrow belt sorters fall into the “divert” category of sortation; divert systems are known for easy maintenance, flexibility, and zone routing applications.

POP UP WHEEL SORTERS

Pop up wheel sorters are used to sort cartons, though it’s not as fast as the other options. It’s ideal for companies that don’t have a permanent space or a large budget for equipment. They’re popular for their functionality and reliability. They’re ideal for retail, auto parts, and the food and beverage industry.

CUSTOM SORTING OPTIONS

When it comes to sorting systems, custom options are also available. Depending on your business model and productivity needs, you may want to consider additional sorting options:

Do you have any questions or queries that remain unanswered? Reach out to the Handling Solutions team today, we’ll get straight to the point and help you find the perfect solution for your material handling operation.

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Conveyor Belts

A GUIDE TO CHOOSING THE RIGHT INDUSTRIAL CONVEYOR BELTS

Industrial Conveyor Belt

Industrial conveyor belts are a vital component in operational efficiency in material handling solutions. But, with so much choice out there — and so many different facts and figures relating to each option — how do you make sure you are choosing the right belt for your business?

We want to make the selection process easier, empowering you with the information you need to make the right choice. With this in mind, we created this handy guide to selecting the ideal industrial conveyor belt system.

10 CONSIDERATIONS WHEN CHOOSING AN INDUSTRIAL CONVEYOR BELT

ULTIMATE TENSILE STRENGTH

Ultimate Tensile Strength, or UTS, is a strength rating that is applied to industrial conveyor belts. It refers to the maximum force that a conveyor belt can withstand before it begins to lose its structural integrity — something that may result in the belt stretching or even breaking. Conveyor belts designed for more heavy-duty industrial applications will have a higher UTS rating. As the rating is universally applied, you will be able to use it as you compare products from different conveyor belt manufacturers.

MAXIMUM WORKING TENSION

While the UTS refers to the tensile strength limits of the conveyor belt at rest, the Maximum Working Tension rating is arguably more useful in industry. This rating refers to how much tension a conveyor belt can withstand during its operation without sustaining damage. While the conveyor belt may not be under as much strain as a component like a power transmission belt, it will still need to be able to operate at a certain level of tension. Again, conveyor belts deployed in heavy industry are likely to feature high Maximum Working Strength ratings.

IMPACT RATING

Depending on the use case for your conveyor belt, the impact rating may be something you need to consider. This rating refers to the force that the belt is able to withstand in the event of an object falling onto it from a height. In many applications, this will be a regular occurrence as rubble or other heavy materials may need to be deposited on the conveyor from a hopper or conduit. If your facility handles food processing or other lighter-duty activities, this may not be so important. But, it is something that those working in heavy-industry will need to be aware of.

OPERATING ENVIRONMENT

The environment you are operating in must be taken into account when you select an industrial conveyor belt. If you are working in an anti-static environment, or anywhere deemed high-risk due to flammable particles in the atmosphere, you need to make sure that the belt you choose is rated for this application. Failing to make sure of this could leave you, your team, and the general public at risk.

BELT FLEXIBILITY AND PLIABILITY

In some instances, it may be necessary to manipulate the conveyor belt into a trough shape to aid the transportation of materials. If this is the case at your facility, you will need to make sure that the belt is up to the task. Make sure it can be easily manipulated into shape by the belt rollers before returning to the standard flat profile when it cycles back to the beginning of its route. The belt will need to maintain its rigid structure when it is troughed, bending at key points rather than sagging, and should not become pinched by the supporting structure.

TRANSITION DISTANCE

The transition distance is another important consideration if you need to manipulate your conveyor into a troughed profile. This refers to the distance that the conveyor belt will need to travel in its flat, un-angled profile before it reaches the point of transition into the troughed profile. It all comes down to the angle at which the belt will be troughed. The greater the angle, the greater the transition distance will need to be. Operating with a transition distance that is too short could put undue stress and strain on your belt during operation.

GRADIENTS

If you need to transport materials and products from one level to another, it will be necessary to angle your conveyor to form a gradient. For this application, the flexibility and pliability of the conveyor belt itself, mentioned above, will come back into question. You will also need to choose a belt with an appropriate level of surface layer friction to transport items efficiently up the slope.

COVERAGE

A conveyor belt is a durable piece of hardware that is designed for industrial applications. However, this does not mean that it is not susceptible to wear and tear, or that you can’t take steps to extend the life of the equipment. If you are working with materials that feature sharp edges, are corrosive, or may be falling onto the belt from a height, you may decide to opt for a conveyor belt with a protective layer to keep your equipment running smoothly and effectively for longer.

INTEGRATION WITH OTHER EQUIPMENT

Will your warehouse conveyor system require a simple transition from point A to point B, or is it a little more complicated, interacting with other pieces of equipment in your facility? This is something to consider when selecting your conveyor belt, as you will need to make sure that the belt can efficiently transmit material to where it needs to be. Structural connection points can help you to achieve this with your conveyor belt set up.

CONVEYOR ROUTE

It may be necessary for your industrial conveyor belt to go around corners or to change direction. This will be possible with many types of conveyor belts, but these belts may not be suitable for all applications. For example, if it is critical that your products and materials maintain a consistent orientation at all points on the route, you may need to install structural elements within your system that make this possible.

GET THE RIGHT CONVEYOR BELT FOR YOUR BUSINESS

If you still have questions, you can always reach out to our friendly and knowledgeable team. We can help you determine the best conveyor system according to your current space, business model, vision for growth, and budget. 

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Conveyor Systems

SELECTING THE RIGHT PALLET CONVEYOR SYSTEM

If you’re researching a pallet conveyor system, it’s no small task. The design, operation, cost, and role in your business make it one of the most important decisions in materials handling solutions industry. Use this list as a guide to help you identify the most important considerations for efficiency, safety, and increases in production.

USE OUR CONVEYOR SYSTEMS CHECKLIST AS A STARTING POINT: 

MODULAR PALLET CONVEYOR SYSTEM

How your pallet conveyor will meet your needs today and continue to meet those needs tomorrow and in the long term is a critical part of the selection process. A modular system enables you to easily scale your conveyor as your business and your facility evolve over time.

A modular pallet conveyor system is the ideal solution when you are searching for a combination of scalability and portability. A modular design is a combination of parts and accessories that are interchangeable and easily reconfigured. Modular designs are ideal for rented warehouse space; when the lease is up, your conveyor system can be broken down into parts and assembled in your next location. Modular systems are also a good choice if your industry is experiencing many technological changes and upgrades. Instead of replacing an entire conveyor system at one time, you can replace specific parts and equipment to work with the latest material handling advancements.

POWER & PRODUCT

Power pallet conveyor systems are either powered by motorized chains, roller beds, or a combination of both. In addition to total load capacity, consider the requirements for speed, positioning accuracy, frame configuration. Motorized chains are used primarily in material handling applications for moving large, heavy objects including crates, drums, or pallets in heavy-industry settings. Wheel conveyors use gravity or manual power to move pallets.

MATERIALS & ENVIRONMENT

Your pallet conveyor system will need to function in the temperature range of your warehouse and withstand damage from high humidity, extreme temperatures, industrial cleaners, or other industry specific conditions. Ask about stainless steel conveyors, anti-corrosive options, and systems that are designed for your industry.

SAFETY

The placement of the chains or beds is important for worker safety and OSHA compliance. Ask your supplier about safety accessories, such as partitions, walkways, panels, bumpers, railings, and lifts.

ZONES

Pallet conveyors can be set up in a collection of zones to include multiple operations, connect buildings, and serve as buffers to keep products separated. If pallets require zero contact and zero pressure, zero contact zoned conveyors are your best choice.

ACCESSORIES AND CUSTOMIZATION

Depending on your warehouse footprint and operation, your performance requirements, other pieces of equipment to maximize efficiency and improve worker safety. Be sure to ask about these accessories as you research your ideal conveyor system:

  • A pallet unloading system
  • Robotic palletizer
  • Transfer carts
  • Stackers/destackers
  • Turntables
  • Positioners/Levelers

Finding the right combination of products and configuration for your pallet conveyor system is much easier when you have an expert material handling solutions team on your side. Our team at Handling Solutions, Inc. is on hand to help you find that ideal pallet conveyor system that supports the needs of your business in the short and long term, meets industry guidelines, and fits your project timeline. Reach out to the Handling Solutions team today, we’re here to help you succeed.