Modern warehouses and distribution centers are larger and more complicated spaces than ever before, and today’s customers also have higher standards than they did in the past. Goods of all shapes and sizes need to move quickly and efficiently through these spaces, so that orders can be fulfilled accurately and quickly enough to keep consumers satisfied and operations flowing smoothly.
Fortunately, various advanced tools and technologies are available to assist with this, and the automated conveyor system is the perfect example. A revolutionary piece of automated material handling technology, this system allows goods to be easily transported, sorted, and tracked across vast warehouses and manufacturing facilities, dramatically reducing the burden on the workforce.
As your automation experts, the BoxLogix team will use this guide to demonstrate how automated conveyor systems work, the benefits they bring, some common applications (like e-commerce fulfillment), and the key factors before investing in automated conveyors of your own.
An automated conveyor system is a mechanized piece of warehouse equipment designed to transport products and materials along a fixed path without the need for continuous human intervention and oversight. This separates it from manual material handling, which relies on workers to push, carry, or otherwise move items from one section to the next.
Key components of this type of sortation system include: sensors and controls that help to regulate movement and spacing between goods; drive mechanisms, like a drive motor, to actually provide physical motion; a programmable logic controller (PLC), which monitors sensors and switches and activates or deactivates motors; and software, like a warehouse management system (WMS).
Automated conveyors are found in the majority of modern warehouses and distribution centers, particularly medium- to large-scale facilities. They may be just one piece of a larger warehouse automation system and work together with other advanced technologies to find, move, and store goods, or can operate on their own.
The exact way in which automated conveyor systems work can vary based on the exact type of conveyor being used and how deeply it’s integrated into the broader automated environment. However, most systems follow a familiar multi-step process, which begins from the moment an item is first placed onto the conveyor.
At that exact moment, scanning technologies, such as overhead cameras or barcode scanners, verify the product’s identity or read its unique label. The item then moves along the automated belt, with light-beam sensors tracking as it progresses from point to point, providing real-time data to the wider system about the precise locations of goods at any given moment.
Control systems determine the movement speed, direction, and timing as the product continues its journey, communicating constantly with primary programs, like a WMS or warehouse control system (WCS), which can tell the conveyor where the item needs to go. Once it arrives at its destination, workers can collect it manually, or other automated systems, like robot pickers, can retrieve it instead.
The overarching goal of an automated conveyor system like this is to create a coordinated and reliable flow of materials across the warehouse, with fewer bottlenecks and delays, while also reducing the need for workers to manually push, lift, or carry them between zones. Such systems can play crucial roles in optimizing operations and making sure that orders are processed and shipped out on time.
An automated conveyor system relies on a combination of mechanical equipment, sensors, controls, and software to keep products moving efficiently. While the exact components vary by system and application, most automated conveyors include several core elements that work together to control movement, track products, and maintain a consistent material flow.
Automated conveyors typically include:
From the classic belt conveyor to the tubular cable conveyor and more niche varieties (like zero-pressure accumulation conveyors), automated conveyor systems come in various forms. Each type is designed for different products, loads, facility layouts, and material handling needs.
Some of the most common types of automated conveyor systems include:
These are made up of flat surfaces (usually rubber or fabric) that are well-suited for transporting small, light, or irregularly shaped items.
A roller conveyor is made up of a series of cylindrical tubes that can be either motorized or powered by gravity to transport heavier items, like totes, pallets, and boxes.
As the name suggests, these automated conveyors are specifically for the movement of palletized loads. They’re common in manufacturing and distribution facilities.
An overhead conveyor is positioned in an elevated position, above the warehouse floor, in order to preserve floor space for other uses, like storage.
These conveyors move goods vertically, between different floors or levels of a facility, and are most common in large-scale warehouses.
Automated conveyors do much more than simply move goods from point A to B. They can have a tangible positive impact on the efficiency of the entire material handling process.
Some of their many benefits include:
Automated conveyors keep goods moving almost constantly, minimizing needless delays between operational processes. This, in turn, can improve throughput, especially when dealing with higher volumes or periods of peak demand.
Without automated conveyors, workers would be responsible for carrying, pushing, and moving goods from one point to another. Yet, with them, workers have more freedom to focus their efforts on other, higher-value tasks.
Since workers don’t have to spend as much time carrying and transporting goods, the presence of automated systems can reduce some manual-handling risks and worker fatigue. They also have helpful safety features of their own to keep accidents to a minimum.
With their various scanners and sensors, automated conveyors facilitate accurate tracking of products and materials as they travel across the warehouse. This makes it easier to ensure that goods get to the places they need to be and can also reduce the risk of tracking and routing errors.
Automated conveyors create predictable movement chains for products throughout their time in the warehouse. From reception through to storage, picking, packing, and shipping, conveyors play their part in each stage of the journey, which also aids with inventory tracking and operational optimization.
Automated conveyor systems are found in:
It’s worth noting, however, that even though automated conveyors are found in such diverse fields, they can vary quite widely from one sector to the next, and it’s important for companies to select the right type of conveyor to fit their specific needs.
Conveyors are often just one piece of larger automated warehouse systems, which can include WMS programs, automated sortation systems, barcode scanners, robotic pickers, and so on. They can interact with these other pieces of warehouse technology in various ways to make the overall operation even more efficient.
Automated conveyors can feed and receive information to and from a WMS, for example. They can deliver goods to automated sorters or robot pickers. They also often work in conjunction with barcode and RFID scanners, which track items as they move along, and pick-and-pack systems, which group goods together in packages, ready for shipping, once they reach the end of their conveyor route.
Often, a WMS or some sort of centralized control or software system is like the brain of the warehouse, while automated conveyors are the muscle; the centralized software dictates movement, speed, and routing, while conveyors do the heavy lifting.
Vision systems can also work in conjunction with conveyors to help workers inspect products, verify labelling, identify errors and defects, or confirm that items are correctly positioned in the process.
Automated conveyors can be considerably beneficial for modern warehouses and distribution centers, but that doesn’t mean they’re a universal fit for every operation. Facilities should consider a range of factors before investing in these systems, such as:
Keep in mind that automation should be brought in to solve problems or address challenges your facility faces. It shouldn’t just be installed because it seems necessary.
Automated conveyor systems can speed up product movement, improve throughput, enhance safety, and help you get more from the labor force at your disposal. But in order to enjoy those benefits, you need to make sure you choose the right system to match the products, processes, layouts, and needs of your facility.
That’s the challenge. And if you’re not quite sure how to address it, BoxLogix is here to help. We have years of experience in warehouse automation and have helped countless companies choose the right systems and develop strategies that work for them.
Contact our team today and find out how we can help you design an automated conveyor solution that aligns perfectly with your operational goals.
An automated conveyor uses sensors, controls, software, and other technologies to move and route products with minimal human intervention. Traditional conveyors may still move products mechanically, but typically rely more heavily on workers to control, monitor, sort, or direct the flow of goods.
Automated conveyor systems can transport a wide range of products, including boxes, totes, pallets, packaged goods, manufacturing components, and food and beverage products. The types of goods a system can handle depend on factors like their size, weight, shape, and the type of conveyor being used.
Automated conveyor systems improve warehouse efficiency by keeping products moving consistently between receiving, storage, picking, packing, and shipping areas. This can reduce unnecessary worker travel and manual handling, minimize bottlenecks, and help facilities process higher volumes of goods more efficiently.
Yes, automated conveyors can integrate with a warehouse management system (WMS) to help coordinate and track the movement of goods throughout a facility. A WMS can provide information that helps determine where products need to go, while sensors, scanners, and conveyor controls provide data about their location and movement.
Choosing the right conveyor system starts with understanding your products, processes, throughput requirements, facility layout, and existing technology. You should also consider factors like available space, labor needs, expected growth, maintenance requirements, and potential ROI to find a system that addresses your operation’s specific challenges.