Overview
A pop-up transfer conveyor moves product sideways off a line at a right angle. A second set of belts, rollers or chains sits below the main conveyor surface and rises up through it, lifting the item clear of the main line and carrying it away at 90 degrees. When the transfer is done, the unit drops back down and the main line keeps running as normal.
It solves a specific problem: how to get product off one line and onto another that runs across it, without an operator lifting it and without a long diverting curve. Because the transfer unit is built into the line itself, product passes straight over it when no transfer is called for, so the main flow is unaffected.
Pop-up transfers are used wherever lines cross. They feed product from a main run into a packing spur, merge a side line into the main flow, route cases into different lanes, and pull rejects out of a line. In a compact building they are often the only practical way to change direction, because a curve would need floor space that simply is not there.
Belt types
Pop-up roller transfer
Rollers rise between the main conveyor surface to move cartons and totes sideways. Simple and robust for firm flat-based product.
Pop-up belt transfer
Narrow belts lift through the line to carry product across. Better for smaller, lighter or less stable items that need a continuous surface.
Pop-up chain transfer
Chain strands rise to move pallets and heavy unit loads at right angles, typically between chain driven roller conveyor sections.
Bi-directional transfer
Transfers product to either side of the main line, so one unit can feed two destinations or serve as both a merge and a divert point.
Key features
Right-angle transfer in place
Product changes direction 90 degrees within the footprint of the conveyor itself, with no curve and no extra floor space required.
Main line keeps running
When no transfer is called, the unit stays down and product runs straight over it, so the main flow is never interrupted by the transfer point.
No manual handling
Product is moved between lines automatically, removing the lifting and the bottleneck that comes with an operator transferring items by hand.
Merge or divert
The same principle works in both directions, feeding a side line into the main flow or pulling product out of it into a spur.
Space efficient
In tight buildings where a curve will not fit, a pop-up transfer is often the only way to route a line across another without rebuilding the layout.
Sized to your product
Transfer type, lift stroke, speed and drive are set from product base, weight and required rate rather than from a standard module.
Applications
- Transferring between crossing conveyor lines
- Feeding packing and inspection spurs
- Merging a side line into a main run
- Diverting product into lanes
- Removing rejects from a line
- Pallet transfer between chain conveyor runs
- Routing in tight building layouts
- Feeding and offloading production cells
Typical specifications
- Transfer types
- Pop-up roller, pop-up belt, and pop-up chain
- Transfer angle
- 90 degrees to the main line, single or bi-directional
- Lift
- Pneumatic or mechanical lift, rising through the main conveyor surface
- Product types
- Cartons, cases, totes, trays and pallets with a firm base
- Frame
- Painted or galvanised steel, or stainless steel for wash-down areas
- Controls
- Sensor triggered and integrated with the line control system
- Load
- From light cartons to full pallets, depending on transfer type specified
Typical values for this conveyor type. Final specifications are confirmed for your application on quotation.
Frequently asked questions
What is a pop-up transfer conveyor?
A pop-up transfer conveyor moves product sideways at a right angle to the main line. A set of rollers, belts or chains sits below the conveyor surface and rises through it to lift the item and carry it across, then drops back so the main line runs normally again.
When do I use a pop-up transfer instead of a curve?
Use a pop-up transfer when lines cross each other, when you need to move product onto a line running at 90 degrees, or when there is no floor space for a curve. Use a curve when you want the whole line to change direction continuously and you have the room for the radius.
Does the main line have to stop for a transfer?
No. When no transfer is called, the unit stays retracted and product runs straight over the top of it. It only rises for the items being transferred, so the main flow continues around it rather than stopping and starting.
Can it transfer pallets?
Yes, using a pop-up chain transfer, which lifts pallets with chain strands rather than rollers or belts. This is standard between chain driven roller conveyor runs in palletising and warehouse layouts where pallets need to change direction.
Can it move product to both sides?
Yes, with a bi-directional unit. That lets one transfer point feed two destinations, or act as both a merge and a divert depending on what the control system calls for, which saves building two separate transfer points.
What product does it suit?
Product needs a firm, reasonably flat base so it sits stably while being lifted and moved across. Cartons, cases, totes, trays and pallets all transfer well. Very unstable, top-heavy or loose product needs review, since it is lifted and accelerated sideways during the transfer.