Did you know that conveyors are an ancient invention, dating back to the construction of wonders like Stonehenge and the Pyramids Of Egypt? However, their relevance and necessity to modern business have never been greater than today, when fast shipping times and tight margins require the height of efficiency to ensure profitability. 

 

Industries such as packing & shipping, shipping & receiving, warehousing, and manufacturing are all experiencing unprecedented growth in order fulfillment and inventory movement. And the heroes of these processes are conveyors, quickly moving items in and out of facilities.

 

Conveyors Are (VERY) Big Business.

 

The global conveyor systems market size was valued at a whopping $8.8 billion in 2020 and is projected to reach $13.7 billion by 2028, growing at a CAGR (Compound Annual Growth Rate) of 5.8% from 2021 to 2028 (Grand View Research, 2021). Why such astonishing growth? Well, it’s being driven by the increasing need for automation in multiple industries, and the top three benefits of conveyors are impressive to say the least:

 

1. Better Productivity: Industrial conveyors significantly boost productivity by moving your products and materials much more efficiently than manual methods. In fact, according to a recent study by the Material Handling Institute, implementing conveyor systems can increase productivity by up to 30% in warehouse operations.
2. Greater Safety: By reducing the need for manual lifting and handling of heavy items, conveyors provide a much safer working environment for employees The Bureau of Labor Statistics reported that overexertion and bodily reaction (often associated with manual material/product handling), accounted for 31% of all workplace injuries. These injuries can be avoided, and conveyors help mitigate these risks through their ergonomic design and focus on safety.
3. Increased Efficiency and Fewer Errors: Perhaps the greatest strength of conveyors is their ability to streamline operations via a continuous flow of materials. A case study by Cisco-Eagle showed that implementing a conveyor system in a distribution center reduced order processing time by 50% and increased throughput by 40%. What’s more, when you decrease the amount of manual labor involved in a process, you also decrease the error rate significantly. And that translates to saving time and money, and greater customer satisfaction.

 

Other added benefits of conveyors:

 

• Labor Cost Reduction: By reducing the need for, and reliance on, manual labor, conveyors can significantly cut operational costs and decrease production hours. The Conveyor Equipment Manufacturers Association (CEMA) estimates that conveyor systems can reduce labor costs by up to 70% in some applications. That can translate to savings of millions of dollars per year in some of the larger facilities.
• Reduced Downtime: With proper maintenance, conveyors have less downtime compared to manual labor and handling. This much-needed reliability ensures continuous operations and fewer interruptions.
• Heavy Load Capacity: Whether you choose gravity-fed, powered, or standard models, heavy-duty conveyors can easily move products of various weights. In fact, some industrial conveyors can handle loads of up to 1,000 pounds per linear foot.
• Faster Inventory Movement: Conveyors can move items at speeds of up to 600 feet per minute. This is significantly faster than manual methods, and even at this speed, it produces fewer errors than traditional manual labor.
• Optimal Space Utilization: By taking advantage of vertical space and creating organized pathways, conveyors help maximize the use of available floor space. At a time when every square footage counts, this is a great way to get the most bang for your facility’s buck.
• Reduced Product Damage: With proper design, conveyors can significantly reduce product damage during transportation. A study by the Packaging Machinery Manufacturers Institute found that conveyor systems can reduce product damage by up to 80% compared to manual handling.
• Hygiene Maintenance: In industries where cleanliness is crucial, such as food processing, conveyors can be designed to maintain strict hygiene standards.

 

Selecting the right conveyor system for your facility also depends on several factors:

 

1. The Kinds of Items Being Moves: Consider weight, size, shape, and fragility.
2. Volume and Speed: Assess your throughput needs and choose a conveying speed that will do the job.
3. Available space: Carefully measure your facility's layout, workspaces, and other constraints.
4. Integration with current systems: You want to ensure that any new conveyor systems you install are compatible with your current equipment and processes (our experts can help you with this).
5. Budget: You have two costs to consider. First, the initial investment which includes equipment and installation. And then, long-term operational costs and maintenance.

 

The Different Types of Conveyors Available

 

When it comes time to choose a conveyor, you have options. Actually, quite a lot of options. Let’s break them down into the different types and how they differ.

 

SKATE WHEEL CONVEYORS

 

This popular type of conveyor system uses a series of small, free-spinning wheels, often called "skate wheels,” mounted on axles to transport materials. These wheels are typically arranged in rows on a frame, allowing objects to glide smoothly over them, and are commonly used for:

 

• Handling lightweight materials such as moving cartons, trays, or other flat-bottomed items.
• Operations that rely on gravity to move materials down an incline, though they can also be pushed manually.
• Frequent reconfiguration, making them useful in temporary setups or areas where the conveyor layout frequently changes.

 

Within the skate wheel category, you’ll find the following conveyor types.

 

 

ROLLER CONVEYORS

 

Roller conveyors are designed for handling heavier items. They’re robust and can withstand significant weight, making them ideal for industrial applications. They consist of a series of rollers, typically mounted on a frame, that allow objects to roll along the surface. They are comprised of the following components:

 

• Cylindrical rollers that rotate, allowing items to move easily along the conveyor. They can be made from various materials, including steel, aluminum, or plastic, depending on the application.
• A sturdy frame that supports the rollers. It’s usually made of metal and is designed to hold the rollers in place and maintain the overall integrity of the conveyor system.
• Bearings located within the rollers, reduce friction and enable a smooth rotation for efficient movement of products and materials.

• An optional drive mechanism that powers the conveyor, using a motor that drives the rollers. Others are gravity-driven, relying on the force of gravity to move items along the conveyor.

 

Within the roller category, the following types are available to you:

 

Roller Conveyors: Suitable for a wide range of applications, from moving heavy boxes in a warehouse to transporting large components in a manufacturing plant.  

 

 

Other Conveyors

 

 

Accessories:

 

To ensure you have the most efficient conveyor systems, it’s essential to customize them according to your specific needs. Conveyor belt supplies and accessories, such as guides, stops, and diverters, can be used to create the ideal system for your facility.

 

 

Gravity Flow Racks:

 

 

To sum up, conveyors are essential in modern logistics, manufacturing, and warehousing. They’re crucial for improving productivity, safety, and overall efficiency. By selecting the right type of conveyor system and customizing it to meet your specific needs, you can significantly boost your operational capabilities and output. Whether you're handling lightweight packages or heavy industrial components, there's a conveyor solution that can help you achieve your business goals. And as always, the team of experts at Global Industrial is always here to answer any questions you have or guide you in the right direction.

 

The information contained in this article is for informational, educational, and promotional purposes only and is based on information available as of the initial date of publication. It is the reader’s responsibility to ensure compliance with all applicable laws, rules, codes and regulations. If there is any question or doubt in regard to any element contained in this article, please consult a licensed professional. Under no circumstances will Global Industrial® be liable for any loss or damage caused by your reliance on this article.