Types of Conveyor Systems and How to Select One

Types of Conveyor Systems and How to Select One

Conveyor systems are available in many forms to accommodate varied product shapes, weights, line speeds, and facility constraints. Selecting an appropriate type requires understanding each technology's strengths and limitations as well as how it will interact with downstream equipment and operational processes. Below is a detailed guide to common conveyor types and selection criteria.

Common conveyor system types

• Belt conveyors: Continuous loop belts made of rubber, PVC, polyurethane, or fabric. Ideal for handling lightweight to medium-weight cartons, bags, totes, and loose items. Belt conveyors are versatile and can be configured for inclines, declines, and curves.

• Roller conveyors: Gravity or powered rollers that move loads with flat bottoms such as cartons or totes. Gravity rollers are simple and low-cost for accumulation and staging; powered rollers (live roller) deliver active movement and are common in sortation.

• Chain conveyors: Heavy-duty conveyors using chains instead of belts. Suitable for high temperatures, heavy loads, or palletized items. Common in automotive or heavy manufacturing.

• Screw conveyors: Helical flights inside a tube or trough for moving bulk solids like grains, powders, or wet materials. Best for enclosed, controlled transfer of bulk flow materials.

• Modular plastic conveyors: Interlocking plastic modules form a durable surface that resists abrasion, chemical exposure, and moisture. Widely used in food, beverage, and washdown environments.

• Pneumatic conveyors: Use air pressure or vacuum to move lightweight bulk items or dust materials through piping. Often used for powders, granules, and small components in food or pharmaceutical plants.

• Overhead conveyors: Suspended systems for hanging garments, engine parts, or assemblies. Overhead conveyors free valuable floor space and are used in assembly and finishing operations.

• Vertical conveyors and lifts: Elevate products between floors or mezzanines. Spiral conveyors, bucket elevators, and vertical reciprocating conveyors (VRCs) optimize facility footprint where horizontal space is tight.

• Magnetic conveyors: Move ferrous parts via magnetization; used in stamping and welding operations to hold and convey metal pieces securely.

• Sortation conveyors: Specialized conveyors that direct items to specific destinations using pusher, tilt-tray, cross-belt, or pop-up wheel mechanisms. Essential for high-volume distribution and parcel operations.

Selection criteria

When choosing a conveyor system, evaluate the following variables:

• Product characteristics: Weight, dimensions, center of gravity, fragility, and surface condition (e.g., slippery or porous). Fragile or irregularly shaped items may need tailored fixtures or gentler accumulation methods.

• Throughput and speed: Required units per hour and peak loads determine motor sizing, belt width, and accumulation schemes.

• Layout and footprint: Floor space limitations drive decisions between horizontal, vertical, or overhead options. Curved conveyors and spiral lifts can optimize limited footprints.

• Environment: Temperature extremes, washdown requirements, dust, or corrosive chemicals influence material selection—stainless steel and modular plastics for hygiene; chain conveyors for hot or abrasive conditions.

• Incline/decline needs: Steep inclines may require cleated belts, cleats on modular conveyors, or specialized friction surfaces to prevent slippage.

• Integration and automation: Compatibility with PLCs, WMS, robots, scanners, and sorters influences control architecture and sensor placement.

• Maintenance and downtime tolerance: Simpler systems have lower maintenance demands but may not achieve required throughput. Consider ease of access, modular replacement parts, and service agreements.

• Cost and total cost of ownership (TCO): Evaluate capital expenditure against operating costs—energy use, spare parts, labor for maintenance, and expected lifecycle.

Comparative advantages and typical uses

• Belt conveyors: Good for continuous, gentle transport; minimal product damage; common in packaging and light manufacturing.

• Roller conveyors: Efficient for hard-bottom loads, pallet flow, and sortation lines; lower friction and energy needs for gravity systems.

• Chain conveyors: Best for rugged, heavy-duty material handling and harsher environments like metalworking shops.

• Modular conveyors: Excellent for washdown and food processing where hygiene is critical and belts would degrade.

• Pneumatic conveyors: Specialized for bulk powders and small components where containment and dust control are important.

Practical selection process

• Document product specifications and operational targets, including throughput, shifts, and future growth projections.

• Map process flows and facility constraints, including loading/unloading points and interfaces with existing equipment.

• Shortlist conveyor types that meet product and environment requirements, then model throughput and floor layout.

• Conduct risk assessment for safety, contamination, and product damage. Specify guarding, sensors, and emergency stops accordingly.

• Request vendor proposals with detailed TCO, spare parts recommendations, maintenance plans, and integration services.

• Consider pilot testing or prototype sections before full deployment to validate assumptions under real operating conditions.

Summary

Choosing the right conveyor system is a balance of technical fit, operational goals, and lifecycle economics. By systematically evaluating product needs, throughput requirements, environmental constraints, and integration capabilities, operations can select a solution that maximizes efficiency, reduces risk, and supports future scalability.