Roller Conveyor System

More About Roller Conveyors

A roller conveyor, also named roller conveyor table, is a system designed to transport items, commonly used in warehouses, manufacturing plants, and distribution centers. It consists of a series of rollers mounted on a frame, allowing items to move smoothly from one point to another. Roller conveyors can be either powered or gravity-fed, depending on the specific requirements of the operation. According to the weight of the transported materials, it can be divided into light, heavy and heavy-duty roller conveyors.

Driven Types of Roller Conveyors

• Gravity Driven: Rollers move items by gravity or manual push. Best for lightweight loads or short distances on a decline.
• Belt-Driven : A continuous belt (e.g., flat or V-belt) runs beneath the rollers, driving them via friction. Best for medium loads.
• Chain-Driven: Chains connect rollers, typically via sprockets, driven by a motor. Ideal for heavy loads or harsh environments.
• Motorized Roller (MDR): Each roller (or select rollers) has an internal motor, powered by low-voltage electricity. Used in zero-pressure accumulation systems and modern automated setups.
• Line Shaft: A single rotating shaft runs along the conveyor, connected to rollers via belts or bands. Best for light/medium loads.

Key Components of Roller Conveyors

• Conveyor Rollers: Cylindrical tubes made from metal (carbon steel, stainless steel), plastic, or composite materials. They vary in diameter and spacing based on load requirements.
• Conveyor Frame: Structural support (steel, aluminum) that holds rollers in place.
• Drive System: Powered Motors with belt, chain, or line-shaft mechanisms; Motorized Drive Rollers (MDR) have integrated motors.
• Non-Powered: Relies on gravity (declined) or manual force.
• Bearings/Ends: Enable smooth roller rotation.
• Controls: Variable speed drives, sensors, PLCs for automation.

Advantages of Roller Conveyors

• Efficient Straight-Line Transportation: Roller conveyors excel at moving goods in a straight path, making them highly efficient for transporting items between fixed points, such as workstations or across a warehouse.
• Simple Installation and Maintenance: Their straightforward design makes roller conveyors easy to install and maintain. Gravity-fed systems, in particular, have fewer moving parts, reducing the need for frequent upkeep.
• High Load Capacity: Designed to handle heavy items like pallets, large boxes, and industrial equipment, roller conveyors—especially those with steel rollers—are ideal for heavy-duty applications.
• Versatility in Design: These conveyors can be customized with adjustable roller spacing, height, and optional features like curves, allowing them to adapt to various facility layouts.
• Reduced Manual Handling: By automating the movement of goods, roller conveyors decrease the need for manual labor, lowering labor costs and reducing the risk of worker injuries.
• Low Operational Costs: Once installed, gravity-fed roller conveyors have minimal operational costs due to their simplicity and lack of power requirements.
• Energy Efficiency (Gravity-Fed Systems): Gravity roller conveyors rely on gravity rather than electricity, making them a cost-effective and energy-efficient option for short-distance movement.

How to Choose Roller Conveyor?

Choosing the right roller conveyor depends on various factors, including load type, weight, environment, and operational requirements. Here's a step-by-step guide to help you select the best roller conveyor for your needs:

1. Determine the Load Type & Weight

• Light Loads (Cartons, Small Boxes) → Gravity Roller or Belt-Driven Conveyor
• Medium Loads (Crates, Totes) → Powered Roller Conveyor
• Heavy Loads (Pallets, Metal Parts) → Chain-Driven or Pallet Roller Conveyor

2. Select the Roller Type & Material

• Steel Rollers – Best for heavy loads and industrial environments.
• Plastic Rollers – Suitable for lightweight applications and corrosive environments.
• Rubber-Coated Rollers – Provides grip and reduces noise.
• Stainless Steel Rollers – Ideal for food processing and wet environments.

3. Choose Between Powered vs. Gravity Roller Conveyor

• Gravity Roller Conveyor – Uses slope or manual push, best for simple movement of goods.
• Powered Roller Conveyor – Uses motors to move loads automatically, ideal for high-volume operations.

4. Consider Roller Spacing & Diameter

• Roller Spacing: The spacing should be ≤ 1/3 of the shortest load length to ensure stability.
• Roller Diameter - Small (20-40mm) – For lightweight items.
• Roller Diameter - Medium (40-80mm) – For general industrial use.
• Roller Diameter- Large (80-150mm) – For heavy-duty applications.

5. Select the Frame Material

• Mild Steel – Strong and cost-effective for general use.
• Aluminum – Lightweight and corrosion-resistant.
• Stainless Steel – Best for food, pharmaceutical, and corrosive environments.

6. Consider Environmental & Operational Factors

• Wet/Dusty Environment? → Use sealed bearings and stainless steel rollers.
• Temperature Sensitivity? → Ensure rollers and materials can handle extreme temperatures.
• Noise Control? → Use rubber-coated rollers or precision bearings.

7. Determine Additional Features

• Accumulation System – Stops or holds loads without back pressure.
• Side Guides & Guardrails – Prevents products from falling off.
• Speed Control – Regulates conveyor speed for smooth operation.
• Adjustable Height – Allows flexibility in different setups.

Would you like assistance in selecting a roller conveyor for a specific application?