Live Roller Conveyor

Transforming operations with unparalleled precision and seamless product flow, driving exceptional productivity gains.

Live roller conveyor systems are known for revolutionizing warehouse operations by dramatically improving workflow efficiency. They can increase throughput by up to 30% and cut processing times by 20%, driving significant productivity gains.

With added features to implement accumulation and sortation technology, these systems further boost efficiency by as much as 50%, streamlining order fulfillment and enabling high-speed processing. When outfitted with advanced 24-volt DC motors, they deliver up to 60% in energy savings, reducing operational costs while maximizing overall performance.

What is a Live Roller Conveyor?

A live roller conveyor, also called powered roller conveyor, is a powerful, efficient conveyor system designed to move items with flat bottoms – such as boxes, totes, and pallets – over distances within a facility.

Unlike traditional conveyors, which often rely on gravity or manual pushing, live roller conveyors are equipped with motorized rollers powered by belts or chains with efficient motors to drive consistent, controlled movement. 

Two Types of Powered Roller Systems

When it comes to motorized roller conveyors, two main types offer distinct advantages for diverse operational needs.

1. Belt-Driven Live Roller Conveyor (BDLR)

Operate by using a motorized belt that runs beneath rollers, providing controlled, friction-based movement to items placed on top. As the belt moves, it makes contact with the rollers, which in turn propel the products along the conveyor line. This design provides smooth, controlled movement ideal for friction-driven transport tasks, making them perfect for lighter loads that require precision handling.

2. Chain-Driven Live Roller Conveyor (CDLR)

Use a series of interconnected chains to drive the rollers. The chains engage with sprockets on each roller, creating robust torque that powers heavy-duty operations. Excels in heavy-duty operations, delivering exceptional torque to handle large, bulky items with ease.

Benefits of Roller Conveyor with Motorized Drive

Live roller conveyors stand out with their adaptability, seamlessly handling complex layouts involving merging, diverging, and product accumulation. Their low-friction bearings boost energy efficiency without sacrificing productivity.

Suitable for diverse applications, they excel in picking, packaging, and assembly lines. Designed for smooth transport across horizontal and curved paths, they optimize material flow. With customizable control points and enhanced safety features, they provide precise handling and a safer work environment.

• 60% Energy Savings: 24-volt DC motors can achieve energy reductions of up to 60% compared to traditional conveyor systems.
• 30% Throughput Increase: Throughput increases of up to 30% with the implementation of automated conveyor systems.
• 20% Reduced Processing Time: Decreased processing times by approximately 20%, enhancing overall operational efficiency.
• 2X to 3X Boost with Accumulation: Doubles and triples efficiency with accumulation applications – influenced by factors such as conveyor speed, product length, and the chosen release mode.
• 50% Enhanced Sorting Efficiency: Sorting speed improvements of up to 50%, streamlining order fulfillment processes.

Cost Savings & Operational Advantages

Investing in live roller conveyors delivers impressive financial advantages that translate directly into a strong ROI. With durable, modular components, maintenance costs are kept low, saving money on upkeep over time.

Custom configurations allow businesses to tailor solutions, ensuring every dollar spent maximizes operational efficiency. Automation reduces labor expenses by streamlining transport and cutting down on manual handling. Energy-efficient drives optimize power usage, reducing operational costs without compromising performance.

• Custom Configurations: Tailored designs provide a high ROI.
• Reduced Labor Costs: Automation streamlines transport and minimizes manual labor.
• Energy-Efficient Drives: Lower operational costs through optimized power usage.
• Minimized Downtime: Reliable performance boosts productivity.
• Scalability: Easily upgrade and expand as your business grows, ensuring future-proof efficiency.
• Lower Maintenance Costs: Durable, modular components minimize upkeep expenses.

Custom Options

Built to support evolving workflows, live roller conveyor systems deliver exceptional agility and adaptability through extensive customization options for any industry demand. Tailored dimensions, diverse roller materials, and specialized configurations ensure precise alignment with unique operational needs.

The modular design enables seamless integration of features like automated controls, package stops, and diverting mechanisms, driving both efficiency and functionality. Versatile solutions provide for both accumulation and sortation applications, ensuring efficient material handling tailored to any operation. 

• Accumulation and Sortation: Serves applications for zero-pressure accumulation and advanced sortation facilitating precise product flow.
• Custom Dimensions: Tailored height, width, and length to match operational needs.
• Customizable Curves: Navigates complex layouts with ease, optimizing product flow and maximizing space efficiency.
• Flexible Routing: Enables precise merging, diverging, and smooth transitions.
• Roll Spacing Adjustments: Fine-tune spacing to accommodate specific product dimensions.
• Integration Capabilities: Endlessly integrates with complex material handling systems, offering precise, adaptable control for optimized workflows.

Safety & Compliance

Safety is paramount in any operation, and powered conveyors are engineered to prioritize it at every turn. Quick-response emergency stops immediately halt motion when needed, while protective guards shield users from direct contact with moving parts.

Anti-jam designs reduce stoppage risks, minimizing disruptions and hazards in high-paced environments. By meeting strict industry standards, these systems guarantee regulatory compliance alongside efficient operation. 

• Emergency Stops: Quick-response features to immediately halt movement when needed.
• Protective Guards: Prevents direct user contact with moving parts, ensuring safer operations.
• Anti-Jam Designs: Minimize disruptions and safety hazards by reducing the risk of stoppages.
• Regulatory Compliance: Meets industry standards for safe, efficient operation.
• Slip-Resistant Surfaces: Reduce operator risks in material handling.
• Regular Inspection Protocols: Consistent checks and maintenance ensure compliance and operational longevity.

Design & Automated Systems Integration