How Strategic Conveyor Extensions Improved Pallet Flow for a Major Packaging Provider

Challenge: Limited Space, High Forklift Traffic

As production volume increased, finished pallets were accumulating faster than forklifts could remove them. Limited conveyor space at the end of each stretch wrapper line created pressure on operators to clear pallets quickly to avoid a line backup.

One particular line posed a safety and efficiency concern due to its position near a main forklift aisle. The tight layout created traffic jams and slowed both pallet pickup and transport.

To keep operations moving smoothly, the customer wanted to add buffer space at the end of several conveyor lines and find a way to eliminate the traffic conflict between two adjacent lines.

Solution: Extensions, a Curve, and Critical Repositioning

The answer was a combination of smart equipment additions and layout improvements.

Trace and the AEC team extended multiple lines by adding five-foot sections of Hytrol 25-CRR chain-driven live roller conveyor, which is known for its durability and performance in heavy-duty pallet handling applications. These extensions allowed each line to hold more finished pallets and gave forklift operators more flexibility in removing them.

One area required a more creative approach. Instead of simply adding more conveyor in a straight line, the end-of-line flow was reconfigured by incorporating a Hytrol 25-CRRCT 45-degree curve. This redirected the pick point away from a congested traffic aisle and eliminated the overlap with a neighboring line, greatly improving safety and forklift maneuverability.

The controls team skillfully added field wiring to tie the new conveyor sections into the customer’s existing control panel, then reprogrammed the existing PLC for seamless operation.

Result: Improved Flow, Safer Operations

With more pallet capacity now available at each stretch wrapper line, operators are no longer under pressure to rush product off the line. Forklift drivers have a clearer path and more time to safely pick pallets without stopping production.

The layout change that redirected one conveyor line’s pick point resolved a longstanding traffic issue that had caused delays and safety concerns. By eliminating interference between two active lines, the team improved both flow and visibility in a high-traffic area of the plant.

Although the project was originally scheduled to be completed during a planned shutdown, the customer continued production throughout the install. Thanks to strong coordination between AEC’s mechanical team, electricians, and the controls contractor, each line was updated with minimal disruption.

This project is a great reminder that not every improvement needs to be complex to make a big difference. Sometimes, a few feet of additional conveyor and a thoughtful approach to layout can unlock major gains in safety, efficiency, and day-to-day operations.

At Advanced Equipment Company, we bring practical solutions and expert insight to every job, no matter the size. Thanks to Trace Davis and our customer’s plant team for making this one a success.

Conveyor system experts since 1960.

Since 1960, AEC has delivered smart, site-specific conveyor systems built to improve flow, reduce manual handling, and adapt to real-world production demands. Your layout challenges deserve more than a generic fix.