Streamlining Assembly: Hytrol Over-Under Conveyor Boosts Efficiency for Power Transmission Leader

Challenge: Streamlining Assembly Process

When a global manufacturing leader in power transmission parts needed a conveyor system to streamline their assembly process, they turned to AEC and Bart Lassiter, Engineered Systems, Integration & Automation Specialist. The project aimed to improve efficiency while ensuring a smooth, repeatable process for their production line.

Solution: Space-Saving Over-Under Conveyor

The solution was a simple yet highly effective Hytrol over-under conveyor system.

The system design is elegantly straightforward. On the top level, a gravity conveyor carries fixtures holding parts down the line for assembly. As workers build each component, the fixture travels along the conveyor, making stops at various workstations.

Once the part is fully assembled and removed from the fixture, the empty fixture is transferred to the bottom conveyor — a Hytrol E24EZ powered roller conveyor.

The E24EZ is a motorized conveyor powered by 24-volt DC motors, known for its energy efficiency and quiet operation. It gently returns the empty fixtures to the beginning of the line, ensuring a continuous flow in the assembly process. This closed-loop system reduces manual handling, cuts down on unnecessary movement, and keeps the production line moving smoothly.

One of the key benefits of the over-under design is its space efficiency. By utilizing vertical space with a two-tier system, the setup minimizes the conveyor footprint, which is crucial in a busy manufacturing environment. The gravity conveyor on top keeps the assembly process simple, while the powered E24EZ below ensures reliable fixture return without requiring workers to carry fixtures back to the start.

Another advantage lies in the E24EZ’s modularity and ease of integration. Its plug-and-play design made installation swift and straightforward, reducing downtime during the upgrade. Additionally, the system’s low-maintenance requirements ensure long-term reliability and cost savings.

Result: Streamlined Process, Increased Productivity

Thanks to the expertise of Bart Lassiter and AEC, the project was more than just an equipment upgrade — it was a carefully engineered solution tailored to the client’s exact operational needs.

Bart brought a deep understanding of both material handling challenges and system integration, allowing him to design a conveyor setup that not only fit the space but enhanced the entire assembly process. By listening closely to the client’s goals and evaluating their production workflow, he was able to recommend a simple but highly efficient over-under conveyor system that checked every box: reduced manual handling, improved flow, and boosted overall productivity.

Today, this global manufacturer benefits from a cleaner, more repeatable process that supports higher output with less strain on their workforce — all made possible by AEC’s hands-on approach and commitment to solving real-world manufacturing problems.