Use Case – Extending Stainless-Steel Roller Conveyor

The Challenge

A combined food and pharmaceutical distribution centre near Lyon was processing approximately 220 pallets per day through three loading bays. Both incoming and outgoing pallets were moved using manual pallet jacks, short fixed conveyors, and temporary roller tables, which were often shifted around and suffered corrosion from regular washdown chemicals.

This arrangement led to three significant issues. Firstly, each lorry turnaround averaged 45 minutes as staff had to push pallets and cartons across a patchwork of carts and short conveyors. Secondly, the fixed steel tables permanently occupied around 80 m² of valuable dock space, restricting available staging areas. Thirdly, weekly washdowns in the chilled sections resulted in visible rust on painted frames within a few months, causing hygiene failures and frequent replacement of budget equipment.

The Solution

The warehouse introduced two Extend Stainless-Steel Roller Conveyors (550 mm wide, 1,200–5,000 mm long) as gravity-fed links from dock to racking at their busiest doors. Each conveyor is typically used at about 60% of its maximum 5 m extension, providing stability while allowing staff to reach well into trailers or retract the conveyor for space-saving storage.

The stainless-steel construction of both frame and rollers resists daily detergent cleaning and the mildly corrosive, chilled environment. Adjustable height (650–800 mm) enables the conveyors to align with dock levellers and existing pallet wrappers. Staff now transfer cartons directly from the lorry edge onto the extendable conveyor and on to the racking area, eliminating the need for long pushes with pallet jacks and the constant repositioning of temporary tables.

ROI Calculation

Before (Manual carts & fixed tables):

• Average lorry handling time: 45 minutes per vehicle
• Lorries per day: 8
• Total dock handling time: 45 × 8 = 360 minutes (6.0 hours per day)
• Average number of operators: 6.0 h × 2 = 12 labour hours per day
• Labour cost: €20 per hour ⇒ 12 × €20 = €240 per day
• Equipment replacement (rusted carts/tables): approx. €2,000 per year (≈ €167 per month)

After (Extend Stainless-Steel Roller Conveyor):

• New average lorry handling time: 27 minutes (40% faster)
• Total dock handling time: 27 × 8 = 216 minutes (3.6 hours per day)
• Labour time: 3.6 h × 2 = 7.2 labour hours per day
• Labour cost: 7.2 × €20 = €144 per day
• Daily labour saving: €240 − €144 = €96 per day ≈ €2,000 per month (21 working days)
• Rust-related replacement of dock tables almost eliminated: saving ≈ €167 per month

Investment:
Two Extend Stainless-Steel Roller Conveyors at €1,399 each ⇒ total investment: €2,798
Combined monthly savings: €2,000 + €167 ≈ €2,167 per month
Payback period: €2,798 ÷ €2,167 ≈ 1.3 months (conservatively reported internally as less than 5 months including installation and training costs).

Results

During the first three months, the warehouse achieved a 40% reduction in average lorry dwell time, released approximately 20 m² of dock floor area, and cut carton damage at dock edges by half. Hygiene inspections also confirmed the absence of peeling paint and corroded frames in washdown areas.

“The stainless extendable conveyors have given us the versatility of mobile tables without the rust or mess. Dock operations are faster, the workspace is tidier, and we recouped our investment within just a few months.” — Marc Duval, Operations Manager, EuroLog Foods/Pharma, Lyon (FR)