Roller conveyors

What is a roller conveyor?

A roller conveyor is a system consisting of cylindrical rollers set within a robust frame, designed to allow easy movement of different items. This movement may be manual, gravity-driven or powered.

Roller conveyors are suitable for a wide range of uses and can be adapted to meet different requirements. They are effective for moving items such as boxes, cardboard packages, crates, pallets, plastic totes, polybags, slave boards and trays.

To improve functionality, a roller conveyor system can be configured to integrate with additional equipment, such as bends, gates and turntables. This flexibility means roller conveyors can meet a variety of needs in different industrial environments.

Roller conveyors are most commonly used in places such as warehouses and manufacturing plants, where efficient movement of goods is essential.

Using a roller conveyor system adds versatility and can greatly improve the efficiency of a conveyor or automation set-up. These systems are available in materials such as mild steel, galvanised steel, plastic and stainless steel, so you can choose the best option for your durability and environmental needs.

What are the various types of roller conveyors?

Our range includes extendable stainless steel roller conveyors, flexible roller conveyors, motor-driven roller conveyors, powered flex conveyors and truck unloader conveyors. Each type is suited to different tasks, such as loading and unloading, adapting to various layouts or providing powered movement.

In which industries are roller conveyors commonly used?

Thanks to their versatility and wide range of uses, roller conveyor systems are found in many industries, especially logistics and manufacturing. Here are some of the main sectors where roller conveyors are widely used:

1. Food processing: Roller conveyors are important in the food sector for moving products efficiently during processing and packaging.
2. Packaging: The packaging industry uses roller conveyors to organise and transport goods smoothly, supporting the packaging process.
3. Logistics: Roller conveyors are key to logistics operations, ensuring products move efficiently within warehouses and distribution centres.
4. Mail and parcel delivery: Roller conveyors are used in postal and courier services for automated handling and sorting of mail and parcels.
5. Airport baggage handling: In airports, roller conveyors help move passengers’ luggage quickly and reliably between check-in, security and the aircraft.
6. Steel manufacturing: The steel industry uses roller conveyors to move raw materials, semi-finished and finished products within plants.
7. Manufacturing and design: Roller conveyors are fundamental in manufacturing, supporting assembly and movement of components and finished goods.

These are just some examples of the industries that benefit from roller conveyor systems. Their flexibility and reliability make them essential in many sectors.

 

How to choose the right roller conveyor

Use this straightforward process to select the correct conveyor model:

Select the conveyor width you need based on your product size. Allow at least 2.54 cm (1 inch) clearance on each side. If products may move sideways, consider a wider conveyor or side guides.

Decide on the length of roller table required. Standard lengths of around 1.52 metres (5 feet) or 3.05 metres (10 feet) can be joined together. Add curved sections to create your desired layout.

Check the load rating table for each roller’s capacity. Use light duty rollers (about 3.81 cm diameter) for loads under 45.4 kg. Medium duty rollers (about 4.83 cm diameter) and frames are suitable for loads over 45.4 kg. Heavy duty conveyors with rollers of 6.35 cm, 6.67 cm and 8.89 cm diameter are available for very heavy loads.

Choose support centres for the conveyor legs if needed. Provide support at intervals of about 1.52 metres, 2.44 metres or 3.05 metres for all loads.

By following these steps, you can select the right roller conveyor for your needs, ensuring it matches your product size and load requirements.

 

Advantages of gravity roller conveyors

Gravity roller conveyors provide several benefits as they use gravity to move items. When placed on a downward slope, a gravity conveyor allows products to travel without external power. This brings a number of advantages, such as lower costs and greater environmental benefits compared to powered roller conveyors.

1. Cost efficiency: Gravity roller conveyors are highly cost-effective as they do not need electricity or other power sources, which reduces running costs.
2. Environmental benefits: As they do not use power, gravity roller conveyors are more environmentally friendly, helping to cut energy use and reduce carbon emissions.
3. Lower maintenance costs: With no power source, gravity roller conveyors require less maintenance. Fewer components mean lower maintenance costs and less downtime, improving operational efficiency.

However, it is important to remember that gravity roller conveyors may not be suitable for every application. Consider your specific requirements before choosing.

• Limited speed regulation: Gravity conveyors may not offer the same level of speed control as powered models. Where precise movement is essential, for example when transporting heavy goods down steep slopes, a powered roller conveyor may be more suitable to help prevent damage to items.

To sum up, gravity roller conveyors deliver cost efficiency, environmental advantages, and lower maintenance demands, making them a popular option for many material handling tasks. However, it is important to consider your specific operational requirements and any possible challenges to decide whether a gravity roller conveyor or a powered alternative is most appropriate for your needs.

 

What are the benefits of using a powered roller conveyor?

Powered roller conveyors provide several advantages, making them the preferred solution for certain material handling requirements, especially when goods must be moved over greater distances:

1. Effective long-distance movement: Powered roller conveyors are ideal for transporting items over longer spans. Their motor-driven design ensures quick and efficient horizontal transfer of goods.
2. Accurate speed management: These systems allow you to set and adjust the conveyor speed, giving you precise control over the handling process. This helps reduce the risk of accidents and ensures goods are moved safely and accurately.
3. Handling heavier loads: Powered roller conveyors are built to carry heavier items, making them a frequent choice in manufacturing and industrial environments where large or bulky goods need to be moved.
4. Zone control: Powered roller conveyor systems can be split into zones, so each section can be operated independently. This zoning increases efficiency by running only the zones required when items are present, helping to lower running costs and improve overall performance.
5. Fault resilience: If a fault occurs, such as a motor or power failure in one zone, the rest of the system can continue to operate. This built-in fault tolerance helps reduce downtime and keeps operations running smoothly.
6. Automation and reduced manual work: Powered roller conveyors support automation in material handling, cutting down on manual labour. This can boost productivity and make processes more efficient.

Although powered roller conveyors generally involve a higher upfront investment than gravity conveyors, their benefits—such as efficient long-distance transport, precise control, and the ability to handle heavier loads—often make them a sound investment, particularly where automation, safety, and high throughput are essential.

What is a truck unloader conveyor?

A truck unloader conveyor is a specialist conveyor system designed to make loading and unloading goods from lorries and trailers more efficient. These conveyors are often extendable or telescopic, so they can bridge the gap between the vehicle and the warehouse or facility floor. Depending on the application, truck unloader conveyors may be powered or gravity-based, offering flexibility for different operational requirements.

 

When should you use a truck unloader conveyor instead of other conveyors?

Truck unloader conveyors are best suited when the main aim is to speed up the transfer of goods in and out of lorries while reducing manual effort and saving time. They are particularly useful for:

• High-volume logistics sites where fast loading and unloading are needed.
• Warehouses that regularly receive or dispatch lorry deliveries.
• Situations where fixed conveyors do not have the reach or flexibility to extend into vehicles.

Compared to standard roller conveyors, truck unloaders are more mobile and adaptable, making them ideal for temporary or flexible use. Unlike powered roller conveyors, truck unloader conveyors are specifically designed to connect the lorry to the facility floor, serving as a crucial first or last step in the material handling process.

 

Can a truck unloader conveyor be used with other conveyors?

Yes, truck unloader conveyors can be easily combined with other conveyor systems to form a complete material handling solution. Common combinations include:

• Powered roller conveyors: These provide continuous powered movement, making them an excellent extension for moving goods further into the warehouse or production area.
• Powered flex conveyors: These flexible, extendable conveyors can adapt to different layouts and environments, creating a versatile link between the truck unloader and other conveyor systems.

By linking truck unloader conveyors with other systems, companies can create an efficient workflow that reduces manual handling, increases productivity, and ensures smooth movement of goods throughout the site.