Conveyor systems are the unsung heroes of countless industries, driving efficiency and automation in everything from manufacturing to food processing and warehousing. By streamlining the movement of goods, they boost productivity, enhance accuracy, cut labor costs, and improve safety for both products and employees.
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This article explores the different types of conveyor systems, their significant business benefits, how they can be tailored to your specific warehouse needs, and their integration with warehouse automation systems such as Automated Storage and Retrieval Systems (ASRS).
A conveyor is a mechanical handling system used to transport materials, products, or goods within a warehouse or manufacturing facility. It consists of belts, rollers, or chains that move items along a predefined path.
Many types of conveyor systems can be customized to meet a facility's specific requirements and range from simple, manual systems to fully automated solutions.
Conveyor systems vary widely, each with unique features and advantages suitable for different applications:
Conveyor systems are among the most common forms of warehouse automation, and businesses across the globe utilize them to achieve the following benefits:
Manual Conveyor Systems
Manual conveyor systems rely on some human effort to move goods, often involving pushing carts or physically carrying items along the conveyor. These systems are simple, cost-effective, and suitable for smaller operations with lower throughput demands. However, they tend to be less efficient, as they require more labor and are slower than automated alternatives.
Automated Conveyor Systems
Automated conveyor systems use motors, sensors, and control technologies to transport goods with minimal human intervention. These systems are designed to handle large volumes of materials efficiently and are ideal for high-throughput environments. They can also perform tasks like sorting, weighing, and packaging goods automatically. By reducing the need for manual labor, automated systems help cut costs, improve safety, and boost overall productivity. While the initial investment may be higher, the long-term benefits of increased efficiency and scalability make automated systems a valuable asset for growing operations.
A conveyor system consists of several components working together to move materials efficiently. The components can vary based on the system, industry, and materials, and can be tailored to meet specific operational needs. Common components typically include:
Conveyor Belt
The main component that moves materials from one point to another is powered by an electric motor.
Rollers
Mounted individually or in groups, facilitate and guide material movement along the conveyor belt. They support the load and allow smooth movement. Rollers can be powered or unpowered.
Pulleys
Drive and control the belt's movement. Located at each end of the conveyor system, they guide and support the belt.
Motors
Power the belt and control its speed, typically running on electric power. Some motors use variable frequency drives for precise control, while others have multiple motors for flexibility.
Idlers
Support the belt's weight and payload, reduce friction, prevent excessive wear, and ensure proper belt tracking.
Sensors
Detect and monitor object movement on the belt, providing real-time information on position, speed, and orientation for precise control and automation.
Control systems Oversee the conveyor system's operations, including speed, direction, and stops. They consist of a central control panel, programmable logic controllers (PLCs), and software.
Chains
Transfer materials along the system. Made of metal or plastic links, they move smoothly around sprockets or pulleys and come in various sizes and configurations.
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Understanding the unique requirements of the warehouse is the first step in choosing the right conveyor system. Factors such as the type of goods handled, volume of orders, and peak demand periods should be considered. A thorough needs assessment helps identify the tasks that can be automated and the potential benefits of implementing a conveyor system.
ROI: For your ROI calculation, consider the following:
The Exotec Skypod system represents a leap forward in warehouse automation, seamlessly integrating advanced goods-to-person robotics with Skypath®, a plug-and-play automated conveyor solution.
The Skypod system serves as the core of order fulfillment operations, using advanced robotics to automate inventory storage and retrieval. Meanwhile, the Skypath conveyors integrate inbound and outbound operations, creating a seamless and streamlined order fulfillment process. Skypath includes straight, curved, and inclined components, capable of handling up to 2,700 bins per hour at speeds of up to 236 feet per minute.
This powerful combination reduces manual handling, minimizes errors, and significantly reduces processing times. Discover more about the Skypod system and Skypath by taking our virtual warehouse tour.
If you ever had a job where you had to carry heavy objects all day, you probably know about some of the benefits of a conveyor. You might have the back problems to prove it! Whether you're moving minerals and rocks or boxes and food products, it takes a lot of time and effort for human workers to do this. The right conveyor belt can make the job a lot easier for your company. ASGCO is your one-stop-shop for all your conveyor needs. We're here to help you find just the right solution for your company. After you read about the many benefits of moving materials with a conveyor, you can always get in contact with us for more information.
Using a heavy-duty conveyor to haul rocks up a quarry is a little different than moving cookies or pretzels across a room for packaging. Some common conveyor types include belts, rollers, chains, chutes, buckets, and slats. You can acquire horizontal, inclined, or declined devices. Moreover, there are conveyors with turns, angles, and slopes built into them. You can even get a spiral conveyor. As your company continues to grow and develop, your needs may start to change. That's okay. You can always adjust and add onto your current conveyor system. Or, you could install a brand new system that is even more energy efficient.
As a complete conveyor solutions company, ASGCO can provide any type of conveyor system that you need. Because the future of your company may be relying on your conveyor machine, it's important to find just the right solution. The team at ASGCO can make this process much easier for you. Plus, we have technicians who install conveyors and replacement parts.
Any time you need a product moved, a conveyor makes the job much faster and easier for you. A heavy-duty conveyor can keep moving heavy, jagged objects in even harsh conditions. You can have peace of mind knowing that your manufacturing process won't come to a halt. Plus, you won't have to worry about logistics. Placing a product on a conveyor is a lot more simple than having one person separate the items. Then, someone has to carry the individual item and assemble it correctly. Then another person inspects it, packages it, stages it, and places it aside for shipping.
When you have a conveyor in place, you won't need as much labor, helping you save money in the long run. And conveyors do quick work, helping to cut back on your production hours. The faster you move the products down the assembly line, the fewer hours you have to keep the lights on. Across many different kinds of industries, conveyors consistently increase efficiency by 15%.
An automated system can also help you cut back on fuel costs. You may have been using a large truck to move materials, rocks, or dirt. If you do this with a large truck every day, your costs will add up pretty quickly. Conveyors are much more efficient when it comes to fuel and power consumption.
Another benefit of a conveyor system is that it reduces downtime. Even if your factory has a truck or forklift, you still need manpower to load and unload the vehicle and then drive it. With the flick of a switch, you can keep a conveyor working consistently, providing continuous loading and offloading ' as long as it doesn't break down. When you go with a top-of-the-line conveyor system, you won't have to repair it quite as often.
A safer workplace is a happier workplace. With the help of a conveyor, you significantly reduce your chances of operator injury from a worker that is pushing, pulling, or lifting a heavy load. Whether you've been carrying products by hand or by forklift ' a conveyor system eliminates collisions. Now, all of your products will move straight down a fixed pathway. Without human error, you'll have fewer breaks, spills, and drops to deal with. Thus, you won't have to replace as many items, allowing you to meet the needs of your clients.
Companies usually construct conveyor systems with safety in mind, so there are many safety features. Additionally, ASGCO can provide training for properly using the equipment. This can help prevent problems as well as injuries on the job.
In many industries, conveyors have become commonplace. If you don't have a top-quality automated movement strategy, your business may fall way behind the competition. It helps with productivity as well as quality control and customer service. When your conveyor consistently provides the same product each and every time, consumers are able to count on your company. They know exactly what they're getting when they utilize your services.
There are lots of different conveyor applications just within the food industry. A food-grade conveyor belt can help you take baking products from a raw, uncooked stage to a delightful and edible treat. On the other hand, you may use a conveyor to move fruits, vegetables, grains, meat, dairy products, and different types of beverages. When you design your conveyor, you must consider its hygiene, cleaning stops, energy efficiency, and minimization of waste. There will be certain rules and regulations that your system must meet. For example, the Baking Industry Sanitation Standards Committee sets the standards for all baking-related equipment.
A lot of conveyors will move in both directions. This can be extremely helpful if you have products that have to go through a line multiple times before being ready to ship. You just need someone there to work the controls. If you need to slow the conveying system down at any part of production, that's also an option. In addition, there's no height limitation with a top conveyor system. Your factory may have multiple floors. A vertical conveyor can easily travel up and down your factory without the use of elevators or cranes. Generally speaking, a conveyor can travel anywhere you need it to at any time and in any condition.