Optimize workflow by maintaining a continuous, controlled flow of products without interruptions or damage.

Accumulation conveyors are known for significantly improving operational efficiency. They can reduce product handling times by up to 50% and increase throughput by as much as 30-40%, depending on the specific configuration and application. These conveyors allow for smooth and controlled product flow, minimizing bottlenecks and facilitating continuous production.

Additionally, with features like customizable speed control, accumulation conveyors help optimize energy use, often leading to operational cost savings of around 15-20% compared to traditional systems.

 

2 Main Types of Accumulation Conveyor

The two main types of accumulation conveyor systems are zero-pressure and minimum-pressure conveyors.  Both systems improve flow and efficiency but cater to different product handling needs.

 

1. Zero-Pressure Accumulation Conveyor

 Zero-pressure accumulation conveyor is perfect for conveying materials of different size and weight. Products are allowed to accumulate without touching each other. Back pressure is completely eliminated. Ideal for fragile or varied-sized products, the system maintains gaps between items to prevent any contact. 

Product gap is paced by sensor-controlled “accumulation zones” which offers optimal protection for your products from damage and jams. Each zone uses a photo eye to detect products, then keeps them in a separate physical zone. These buffer zones can be used to hold product when downstream processes are not ready for additional product. They can also be used to smooth out production flow fluctuations.

Zero pressure conveyor applications:

  • Buffering products before sortation, kitting, or packaging/shipping areas
  • Feeding palletizing and strapping stations
  • Assembly lines and picking stations

 

2. Minimum-Pressure Accumulation Conveyor

Minimum pressure accumulation conveyor is best used for products of consistent size and weight. Its purpose is to maximize accumulation of product but with a 2% back pressure. This allows light contact between items to create a steady flow, maximizing space usage for durable goods.

Sensor controlled zones allow products to lightly come into contact with each other during accumulation. The cumulative back pressure remains no greater than 2% while products are stopped and waiting for the signal to release.

Minimum pressure conveyor applications:

  • Accumulation of product prior to packing stations
  • Recirculation loops
  • Buffering similar size and weight products
  • Feeding palletizing and strapping stations
  • Assembly lines and picking stations

 

Benefits of Accumulation Conveyor

One of the primary benefits of an accumulation conveyor is its ability to reduce product damage by controlling the flow and buffering items during peak periods of production. It also maximizes operational efficiency by ensuring that upstream and downstream processes aren’t bottlenecked, improving overall throughput.

Additionally, with the ability to tailor systems to specific production needs, accumulation conveyors can accommodate varying speeds, product types, and sizes. This makes them versatile tools that can be adapted to many industries and applications.

  • 50% Decrease in Handling: Cuts product handling time by up to 50%, increasing process speed.
  • 40% Throughput Boost: Enhances throughput by 30-40%, allowing for faster production flow.
  • 20% Energy Efficiency Savings: Offers customizable speed control, leading to up to 15-20% energy savings.
  • 20% Decrease in Product Damage: Provides controlled movement minimizing pressure and damage on products.
  • Minimizes Bottlenecks: Ensures smooth product flow, reducing delays and maintaining continuous operation.
  • Scalable Flexibility: Adapts to varying product weights, sizes, and shapes, providing a dynamic solution that evolves with production needs.

 

Cost Savings & Operational Advantages

By automating the accumulation and buffering of materials, businesses can experience significant cost savings through reduced labor and improved production flow. The controlled handling process minimizes product damage, which in turn reduces waste and rework costs.

Over time, these conveyors also contribute to higher ROI by increasing throughput and enabling operations to scale without requiring major changes to the workforce or infrastructure.

  • Enhanced Productivity: Increases throughput and minimizes downtime, leading to a higher return on investment (ROI).
  • Energy Efficiency: Accumulation conveyors use sensors and controls to reduce energy consumption by stopping and starting only when needed, cutting energy costs significantly.
  • Reduced Labor Costs: Automates the flow of products, reducing the need for manual intervention and minimizing labor expenses.
  • Minimized Product Damage: Gentle accumulation reduces the risk of product collisions and damage, lowering replacement and rework costs.
  • Decreased Downtime: Streamlines product flow, helping to prevent backups and bottlenecks, which leads to less downtime and productivity loss.
  • Lower Maintenance Costs: Designed for efficient, low-friction operation, reducing wear and tear on components and extending equipment lifespan for reduced maintenance expenses.

 

Design, Install & Automated Systems Integration

AEC’s expertise as a premier material handling and automation integrator shines through in designing and integrating highly adaptable accumulation conveyor systems. These systems seamlessly merge with your existing workflows or broader automation setups, effortlessly accommodating various product weights, shapes, and sizes.

With advanced custom configurations each system evolves with the facility’s production needs, delivering a future-ready, flexible solution that grows alongside the business, keeping operations nimble and productivity at peak levels.

 

Keep your workflow rolling smoothly.

Accumulation conveyors are the “traffic controller” of your production line, guiding each product gently, efficiently, keeping product flow running smoothly. Discover how AEC can help streamline your workflow, reduce product damage, and drive efficiency to new heights!

Contact us today for expert consultation.

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Since 1960, Advanced Equipment Company has been providing our services to the Carolinas and throughout the United States.

We look forward to hearing from you and how we can help you with productivity-boosting innovations in automation, material handling, and storage applications.

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