In today’s industrial landscape, efficiency is key. Businesses across sectors like e-commerce, retail, pharmaceuticals, and food processing are turning to automated conveyor systems to boost productivity, reduce manual handling, and streamline logistics.

From belt conveyors to pneumatic systems, conveyor solutions provide reliable, adaptable material handling for various applications. But with so many options, how do you choose the right one for your business?

In this article, we’ll highlight the benefits of different types of conveyor systems and show how we can seamlessly integrate the perfect solution into your workflow.

Introduction to Conveyor Systems

A conveying system is a mechanical handling device used to move goods from one point to another, playing a critical role in various industries due to its functionality and importance. In automated systems, this process is controlled using motors, sensors, and control panels that eliminate the need for manual intervention.

These systems are commonly used in warehouses, factories, fulfilment centres, and production facilities. They’re designed to transport items quickly, safely, and accurately, significantly improving throughput and reducing the need for repetitive manual tasks.

Types of Conveyor Systems

There are many types of conveyors available, each suited to different applications. Choosing the right one depends on your industry, product type, facility layout, and desired automation level.

Belt Conveyors

Belt conveyors are among the most common types of conveyor systems. Known for their versatility, belt conveyor systems efficiently transport materials across various industries, including food processing, manufacturing facilities, and more. With a continuous belt, this system moves materials across a flat or inclined surface, making it ideal for transporting bulk materials or raw materials.

Chain Conveyors

Chain conveyor systems are essential for handling heavier loads compared to belt conveyors. These systems use a chain to pull materials through the system, which is often used for transporting bulk materials, industrial equipment, and heavy-duty items. Chain conveyors are robust and designed to handle large volumes, including dry bulk materials and products in assembly lines.

Pneumatic Conveying Systems

Pneumatic conveyors use air pressure to transport materials through pipelines, making them a great choice for moving bulk materials like granular materials and powders. These systems are highly efficient in industries where space is a premium, as the material is transported via air pressure, requiring less floor space. Pneumatic conveying systems are typically used in food processing, pharmaceutical production, and other industries requiring precise material handling.

Bucket Conveyor Systems

Bucket conveyors, also known as bucket elevators, are ideal for transporting materials vertically. These systems are designed to move materials such as granular materials, bulk materials, and even liquids. They work by scooping materials into a series of buckets that are mounted on a continuous loop, making them ideal for industries like mining, agriculture, and food processing.

Overhead Conveyors

Overhead conveyor systems are designed to transport materials above ground, freeing up floor space. These systems are typically used in manufacturing facilities, where they transport goods or parts along a continuous loop. Overhead conveyors are efficient at moving products in automated systems, reducing manual handling and increasing throughput in production lines.

Roller Conveyors

Roller conveyors, including powered roller conveyors and gravity conveyors, are essential for material handling in various settings. These conveyors are used to transport items along a series of rollers that can either be powered or non-powered. Roller conveyors are widely used in warehouses, sorting facilities, and assembly lines to efficiently move products from one location to another.

Screw Conveyors

Screw conveyors are designed to transport materials using a rotating screw blade within a tube or trough. They are ideal for moving bulk materials like grain, powders, or even liquids in industries such as agriculture and food processing. Their ability to handle difficult materials and keep operations running smoothly makes screw conveyors essential in many manufacturing processes.

Slat Conveyors

Slat conveyor systems are highly durable and used for transporting materials that may be too hot, too large, or too heavy for traditional belt conveyors. These systems use slats made of metal, wood, or plastic to carry products along the conveyor path. Slat conveyors are commonly used in automotive assembly lines and other industries requiring heavy-duty material handling.

Vibrating Conveyors

Vibrating conveyors use oscillating movements to move materials along the conveyor path. These conveyors are ideal for handling bulk materials, particularly when the materials need to be transported in a controlled, consistent manner. Vibrating conveyors are commonly used in the handling of granular materials and dry bulk materials.

Gravity Conveyor Systems

Gravity conveyor systems rely on the force of gravity to move materials along a sloped conveyor track. These systems are often used in warehouses and distribution centres for easy transport of items without the need for external power. They are cost-effective and reliable for the manual handling of lighter items.

Vertical Conveyor Systems

Vertical conveyors are used when space is limited, and materials need to be moved between floors or different levels. These systems are ideal for industries such as food processing, where a continuous flow of materials is necessary. Vertical conveyors often use buckets, spirals, or belts to transport materials efficiently.

Chute Conveyors

Chute conveyors are used to move materials by gravity, typically at steep angles, making them a great choice for transporting bulk materials in warehouses, recycling plants, or manufacturing facilities. These systems are simple and cost-effective for specific material handling applications.

The Benefits of Conveyor Automation

Enhanced Efficiency

Automation focuses on maximising output with minimal input. Conveyor systems can run continuously without fatigue, ensuring steady material transport. This boosts processing speeds and minimises bottlenecks, making them ideal for operations with high throughput demands.

Conveyor systems are designed to handle heavy lifting effortlessly, seamlessly integrating into your workflow to enhance efficiency and provide tangible benefits to your intralogistics.

Increased Safety

Manual handling is a leading cause of workplace injuries. Automating material movement greatly reduces risks such as strain injuries, slips, trips, and falls. Conveyors take over repetitive and heavy tasks, freeing employees to concentrate on more strategic or skilled activities.

Long-Term Cost Savings

Although an initial investment is required, automated conveyor systems often deliver substantial cost savings over time. Lower labour expenses, fewer workplace injuries, reduced error rates, and improved process efficiency all contribute to a stronger bottom line.

Powered roller conveyors, in particular, can enhance cost-effectiveness by efficiently moving products across various material handling applications, reducing manual labour and associated costs.

Scalability

Your conveyor system can grow alongside your business. Modular designs make it easy to expand or reconfigure layouts as your operational needs evolve.

At Connect Storage Systems, we offer both modular and custom conveyor solutions built to the highest UK standards. These systems cater to diverse industries such as e-commerce, food production, and manufacturing, ensuring a tailored fit for your current and future requirements.

Improved Inventory Management

In settings like e-commerce and order fulfilment, conveyor belts can integrate with warehouse management systems (WMS) and automated storage and retrieval systems (ASRS). This integration enables real-time tracking, reduces picking errors, and accelerates order processing.

Key Considerations When Choosing a Conveyor System

Type of Material Being Moved

Are you moving small parcels, large pallets, perishable goods, hazardous materials, semi-solid materials, or granular materials? Understanding the size, weight, shape, and sensitivity of the items will help determine the most appropriate conveyor type.

Facility Layout

The design of your building plays a major role. Narrow aisles, ceiling height, floor load capacity, and the distance goods need to travel all influence the conveyor configuration.

At Connect Storage Systems, we work closely with customers to develop layouts that maximise space and efficiency. Whether you’re installing a new system or upgrading an existing one, our experts can guide you through the process.

Throughput Requirements

High-volume operations demand conveyors that can keep pace. Consider the number of items per hour your system needs to handle and plan for peaks in demand. Vibrating conveyors are particularly effective for these throughput requirements, as they facilitate the gentle transportation of various materials, ensuring minimal damage and optimal distribution. Pneumatic conveyor systems are also highly effective for transferring dry bulk materials, such as powders and granules, through enclosed pipelines, minimising contamination and material loss.

Maintenance and Durability

Downtime can be costly. Look for systems with proven reliability, easy-to-access parts, and local servicing support. Auger conveyor systems, known for their durability and efficiency in transporting bulk materials, are particularly beneficial in reducing spillage and contamination.

Maintenance and Repair

Regular maintenance and repair are essential to ensure the smooth operation of conveyor systems. This includes tasks such as lubricating moving parts, checking for wear and tear, and replacing worn or damaged components. By prioritising maintenance and repair, businesses can prevent downtime, reduce costs, and extend the lifespan of their conveyor systems.

It is important to follow the manufacturer’s instructions for maintenance and repair, as well as to keep detailed records of all activities. Regular inspections and timely interventions can help identify potential issues before they become major problems. By maintaining their conveyor systems properly, businesses can ensure efficient and reliable operation, ultimately contributing to overall productivity and cost savings.

Safety Considerations

Safety is a critical consideration when it comes to conveyor systems, as they can pose various risks to employees and others in the workplace. Common safety hazards include entanglement, pinch points, and falling objects. To mitigate these risks, businesses can implement safety measures such as guards, safety nets, and emergency stop buttons.

Providing employees with proper training on the safe operation and maintenance of conveyor systems is also essential. By prioritising safety, businesses can help prevent accidents and injuries, ensuring a safe and healthy work environment. Implementing comprehensive safety protocols and regularly reviewing them can further enhance the safety of conveyor systems, protecting both employees and the overall operation.

Why Choose Connect Storage Systems?

With decades of experience in automated storage and handling, Connect Storage Systems is a trusted partner for businesses seeking to streamline their operations. Our conveyor systems are tailored to suit a wide range of industries, and we offer both modular solutions and fully bespoke builds. We also provide industrial conveyors designed for safe and efficient material transport in various manufacturing and processing environments.

All conveyors are manufactured to the highest standards in the UK, ensuring reliability, performance, and local support. Whether you’re installing a standalone conveyor or integrating it with your ASRS, Connect Storage Systems provides end-to-end project management, from consultation and design to installation and aftercare.

Our systems are designed to:

• Improve operational efficiency
• Increase safety by reducing manual handling
• Integrate seamlessly with existing infrastructure
• Handle a wide range of product types and volumes
• Support sustainable, long-term growth

When you choose Connect Storage Systems, you’re not just buying a conveyor, you’re investing in a complete solution that adds measurable value to your business.

Summary

In summary, automated conveyor systems play a crucial role in improving efficiency and reducing manual handling across various industries, from e-commerce and food processing to pharmaceuticals and manufacturing. Whether you’re using belt conveyors, pneumatic systems, or chain conveyors, choosing the right conveyor system can significantly streamline material handling processes and increase throughput.

By selecting a system tailored to your specific needs, based on factors like material type, facility layout, and throughput requirements, businesses can achieve long-term cost savings, enhanced safety, and scalable operations.

Frequently Asked Questions