Roller Conveyor Systems

Professional Roller Conveyor Design, Installation

Roller conveyor systems deliver reliable material transport for cartons, totes, packages, and pallets throughout warehouse and distribution facilities. We design and install complete roller conveyor networks using gravity, powered, and accumulation technologies tailored to your throughput requirements, product characteristics, and automation level. Our systems integrate seamlessly with sortation equipment, pick modules, and warehouse management systems.

Roller Conveyor Types, Configurations

Gravity Roller Conveyors: Non-powered roller beds utilizing slight decline (typically 1 to 3 percent grade) for product movement. Steel rollers on ball bearings provide smooth, quiet operation. Roller diameters from 1.4" to 3.5" with centers from 1.5" to 6" depending on product size. Ideal for order picking, packing stations, and short-distance transport where workers manually push products. Curved sections available for directional changes without powered components.

Gravity Skatewheel Conveyors: Lightweight alternative to roller conveyors using rotating wheels on axles. Lower cost and lighter weight than roller designs. Best suited for smooth-bottom cartons and totes. Commonly used in pick-to-light systems, pack stations, and temporary flow rack applications. Portable sections with locking casters enable flexible layout changes.

Belt-Driven Live Roller (BDLR): Powered roller conveyor using continuous belt or chain underneath to drive rollers. Single motor drives entire section, typically 10 to 30 feet. Consistent speed across all rollers ensures even product movement. Cost-effective powered solution for straight sections and gentle curves. Speeds adjustable from 30 to 200 FPM.

Chain-Driven Live Roller (CDLR): Heavy-duty powered roller system using chain linkage to drive rollers. Handles loads up to 4,000 lbs for pallet transport. 2-strand or 3-strand chain configurations provide robust drive for harsh environments. Ideal for manufacturing and heavy distribution applications where durability is essential. Compatible with pop-up transfers for 90 degree directional changes.

Motor-Driven Roller (MDR), 24VDC Smart Conveyors: Advanced technology with individual motors integrated into roller tubes. Each zone operates independently based on photo-eye sensors, creating zero-pressure accumulation to prevent product damage. 24VDC or 48VDC operation provides energy efficiency and simplified wiring. Modular design enables quick zone replacement without extended downtime. Ideal for e-commerce fulfillment, parcel handling, and any application requiring gentle product handling at high speeds.

Accumulation Technology

Zero-Pressure Accumulation: MDR zones stop individually when products enter, preventing contact and damage to fragile goods. Photo-eyes detect product presence and control zone motors independently. Products release sequentially for controlled downstream feeding. Essential for glass, electronics, and cosmetics handling where product damage is unacceptable.

Minimum-Pressure Accumulation: Controlled contact between products using pressure sensors or timing logic. Reduces accumulation length compared to zero-pressure while protecting products. Commonly used in case handling and corrugated box transport where light contact is acceptable.

Slug-Release Accumulation: Accumulates multiple products then releases as a group for downstream processing. Optimizes sortation induction by batching products to sorter capacity. Photo-eye arrays count accumulated products before release.

Curves, Merges, Diverts

Roller Curve Sections: Tapered rollers or individual zone MDR motors navigate 30, 45, 90, and 180 degree turns. Powered curves maintain product speed through direction changes. Minimum inside radius from 18" to 48" depending on product size and conveyor width. Curve banking reduces product shifting on high-speed applications.

Merge Conveyors: Angled induction lanes combine multiple product flows into single line. Photo-eye and PLC logic control alternating merge or priority merge sequencing. Essential for multi-line production feeding single packaging or sortation systems. Typical merge angles: 30, 45, or 90 degrees.

Pop-Up Wheel Diverters: Wheels rise through roller gaps to divert products 90 degrees onto transfer lanes. Diverts activate based on sortation signals, barcode scanning, or manual switches. Handles products from small boxes to full pallets depending on wheel size and motor selection.

Roller Materials, Construction

Steel Rollers: Standard galvanized steel provides durable, cost-effective construction for general applications. Powder-coated options available in various colors. Precision ball bearings ensure smooth rotation and long service life.

Stainless Steel Rollers: Food-grade and pharmaceutical applications requiring washdown capability and corrosion resistance. Sealed bearings prevent contamination. Meets USDA and FDA requirements for food contact surfaces.

Plastic and Composite Rollers: Lightweight, non-marring rollers for delicate product surfaces. Chemical-resistant polymers for harsh environments. Antistatic formulations for electronics handling.

Applications, Use Cases

Order Fulfillment Centers: Pick module transport with gravity and powered rollers moving totes through pick zones, pack station feeding with zero-pressure accumulation buffering orders for packing, sortation induction using metering rollers singulating products for high-speed sorters, shipping consolidation via merge conveyors combining multiple packing lines, and returns processing with manual push gravity rollers at inspection stations.

Warehouse Receiving, Shipping: Dock-to-stock powered roller runs transporting products from docks to storage, cross-docking with continuous flow from receiving to shipping without storage, pallet accumulation using heavy-duty CDLR buffering pallets before stretch wrapping, truck loading with decline gravity rollers easing product loading, and parcel sortation via MDR systems feeding sortation and shipping lanes.

Manufacturing Support: Work-in-process roller conveyors linking production cells, assembly feeding with accumulation zones buffering parts to work stations, quality inspection using manual push rollers at inspection points, packaging lines with powered rollers transporting finished goods to case packers, and pallet building with CDLR accumulating cases for robotic palletizers.

Roller Conveyor Specifications

Load Capacities, Speeds: Light-duty roller conveyors handle loads from 10 to 100 lbs per carton at speeds up to 300 FPM. Medium-duty systems transport 100 to 500 lbs at 60 to 150 FPM. Heavy-duty CDLR conveyors move pallets weighing 500 to 4,000 lbs at 30 to 90 FPM. MDR systems typically operate at 90 to 180 FPM with independent zone speeds for accumulation.

Conveyor Widths, Roller Centers: Standard conveyor widths: 12", 15", 18", 24", 30", 36", 48", 60". Custom widths available. Roller centers (spacing between rollers) selected based on smallest product dimension: typically 1/3 of product length. Common roller centers: 1.5", 2", 3", 4", 6", 9".

System Integration, Controls

Roller conveyors integrate with photo-eye sensors for product detection, barcode scanners for sortation, and programmable logic controllers (PLCs) for complex sequencing. MDR systems communicate via 24VDC networks or industrial Ethernet protocols. Emergency stop pull-cords and safety light curtains provide operator protection. Interfaces available for Warehouse Management Systems (WMS), Warehouse Control Systems (WCS), and Manufacturing Execution Systems (MES).

Maintenance, Support Services

Our local service team provides bearing replacement, roller repairs, motor maintenance, and control system troubleshooting. Preventive maintenance programs include lubrication, alignment checks, and sensor calibration. We stock common replacement parts for rapid response throughout the Northeast & Mid-Atlantic region.

Frequently Paired Solutions

Roller conveyor systems work best when integrated with these proven material handling solutions:

Industries We Serve