Smart Conveyor Extensions Clear the Way for Better Pallet Handling
Even simple projects can carry a lot of weight when they’re tied to end-of-line operations. That was the case when one of the country’s leading packaging providers reached out to Advanced Equipment Company. They needed to improve pallet flow at the end of multiple stretch wrapper lines and eliminate a persistent traffic conflict in one of the busiest areas of their facility.
AEC’s Trace Davis led the job, working closely with the plant team, a controls partner, and in-house electricians to get the work done with minimal downtime, even while production continued.
Industry: Leading full-service packaging provider.
Challenge: Creating more pallet positions in limited, high traffic space.
Solution: Extending lines with Chain Driven Live Roller Conveyor, adding a curve, and strategic repositioning.
Equipment: Hytrol 25-CRR chain-driven live roller conveyor and Hytrol 25-CRRCT 45-degree curve.
Result: A streamlined workflow, reduced manual labor, and improved overall productivity.
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.
Need to Relieve End-of-Line Bottlenecks in Your Facility?
If forklift traffic, pallet backups, or tight spaces are slowing down your operations, AEC can help. Our team specializes in practical conveyor solutions that make high-traffic areas safer, smoother, and more productive.
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. Connect with AEC today to explore a custom solution designed to keep your operation moving – efficiently and safely.
Trace Davis, Automation & Material Handling Specialist
Trace Davis was born and raised in High Point, NC, center of the piedmont triad. After graduating North Carolina State University, he pursued his career within the Automotive Industry. His background consists of MRO Sales, Technical Sales and Aftermarket Parts Sales. He enjoys hands-on projects, where he is eager to see a viable outcome.
Trace’s passion for sales has allowed him to excel by building relationships, creating new opportunities and providing leading customer service. Outside of work, he enjoys spending time with his family, playing golf and staying up to date with the latest technology.
Written by AEC Director of Customer Engagement, Josh Hamrick.
