Professional tools, technical guides, and procurement resources to help you make informed decisions about conveyor systems and material handling automation.
Before contacting suppliers, clearly define your operational needs:
Choose the right conveyor technology for your application:
Best for: Continuous transport of boxes, bags, and irregularly shaped items
Pros: Versatile, handles various load types, smooth transport
Typical cost: $200-800 per linear meter (basic systems)
Best for: Flat-bottomed items (pallets, totes, cartons)
Pros: Low maintenance, energy-efficient (gravity option), modular
Typical cost: $150-600 per linear meter
Best for: Heavy loads (automotive parts, pallets >500kg)
Pros: Extremely durable, handles high temperatures and harsh environments
Typical cost: $400-1,500 per linear meter
Best for: High-speed distribution centers, e-commerce fulfillment
Pros: Automated routing, high throughput (up to 15,000 items/hour)
Typical cost: $500K-5M+ (complete system)
Total Cost of Ownership (TCO) includes:
💡 Expert Tip
For automated systems, expect ROI within 18-36 months for high-volume operations. Manual alternatives may have lower upfront costs but higher long-term labor expenses.
A comprehensive Request for Proposal should include:
⚠️ Common Pitfalls to Avoid
Side-by-side comparison of major conveyor technologies
| Feature | Belt Conveyor | Roller Conveyor | Chain Conveyor | Spiral Conveyor |
|---|---|---|---|---|
| Load Capacity | Up to 300kg | Up to 500kg | Up to 2,000kg+ | Up to 100kg |
| Speed Range | 0.1 - 4 m/s | 0.2 - 2 m/s | 0.1 - 1 m/s | 0.1 - 0.5 m/s |
| Maintenance | Moderate | Low | Moderate-High | Low-Moderate |
| Noise Level | Low (55-65 dB) | Low (50-60 dB) | High (70-80 dB) | Low (55-65 dB) |
| Cleanliness | Good (washdown available) | Excellent | Moderate (open design) | Excellent |
| Best Industries | Food, Pharma, General | Logistics, Warehousing | Automotive, Heavy Mfg | Packaging, Distribution |
Estimate the return on investment for automated conveyor systems vs. manual handling
Annual Labor Savings
$0
Payback Period
-- months
3-Year ROI
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Note: Calculation assumes 70% labor reduction, 250 working days/year, and 5% annual maintenance cost.
Real-world implementations and results
Challenge: Processing 50,000 parcels daily with outdated manual sortation
Solution: Crossbelt sorter with 120 destinations + automated induction
Results: Throughput increased 400%, labor reduced by 65%, error rate <0.1%
Investment: $2.8M | Payback: 22 months
Challenge: FDA compliance issues with existing belt systems
Solution: Stainless steel modular belt conveyors with washdown capability
Results: Zero contamination incidents, cleaning time reduced 75%
Investment: $450K | Payback: 18 months (incl. avoided recalls)
Challenge: Floor space constraints in final assembly area
Solution: Inverted overhead power and free conveyor with vertical lifts
Results: 40% more floor space, cycle time reduced 12%
Investment: $1.2M | Payback: 28 months
Challenge: Temperature-controlled storage optimization
Solution: Mini-load AS/RS with integrated conveyor network
Results: Storage density +220%, picking accuracy 99.97%, energy costs -35%
Investment: $3.5M | Payback: 36 months
Automated Storage and Retrieval System - computer-controlled system for automatically placing and retrieving loads from defined storage locations.
Automated Guided Vehicles / Autonomous Mobile Robots - self-driving vehicles for material transport without fixed tracks.
Conveyor system that allows products to accumulate without contacting each other or stopping upstream flow.
Linear velocity of conveyor belt surface, typically measured in meters/second or feet/minute.
High-speed sortation system where individual belt segments rotate 90° to discharge items to designated chutes.
Mechanical device that redirects items from main conveyor line to alternate paths (pop-up, pusher, or paddle types).
Process of introducing items onto a conveyor system at controlled spacing and orientation.
Powered roller conveyor where rollers are motor-driven (vs gravity rollers).
Point where two or more conveyor lines combine into a single line with gap control.
Plastic conveyor belt made from interlocking modules (vs continuous belt), easier to repair and customize.
Robotic or manual process of selecting items and positioning them onto conveyors or packaging.
Measure of system capacity, typically expressed as units per hour or items per minute.
Warehouse Execution System / Warehouse Management System - software controlling material flow and inventory.
Conveyor technology that stops individual zones to prevent product-to-product contact during accumulation.
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