Overview
A roller conveyor carries product on a series of parallel rollers set into a frame. It suits anything with a firm, flat base, cartons, totes, trays, crates and pallets, and is the standard choice for warehouse, picking and dispatch handling where product needs to move, accumulate and be worked on along the line.
There are two types. A gravity roller conveyor has no motor: product is either pushed by hand or run down a slight fall, so it costs nothing to run, needs very little maintenance and can be moved and reconfigured freely. A powered roller conveyor drives the rollers by motor, giving controlled, consistent movement without manual effort, which is what you need for higher throughput, longer runs and automated layouts.
The two details that decide whether a roller conveyor works properly are roller pitch and roller diameter. As a rule of thumb the product must always be supported by at least three rollers, so the pitch should be no more than a third of the shortest dimension of the smallest item you carry. Roller diameter is then chosen for the load: small diameters for light parcels, larger and heavier-walled rollers for cartons and pallets.
Belt types
Gravity roller
Unpowered rollers, pushed by hand or run on a slight decline. No running cost and minimal maintenance. Used for short transfers, loading docks, pack benches and buffering.
Powered roller
Motor-driven rollers giving controlled, consistent movement. Suited to higher volumes, longer runs, inclines and automated lines where product should not be pushed by hand.
Zero pressure accumulation
Zoned powered rollers that let product queue without pressing against the item in front, protecting fragile goods and preventing jams at pick and pack stations.
Pallet roller
Heavy-duty rollers on a reinforced frame for pallets and heavy unit loads, typically at wider pitch with larger diameter rollers.
Key features
Handles heavy unit loads
Rollers spread load across the frame, so cartons, crates and pallets are carried without the belt wear and stretch you get on a belt conveyor.
Natural accumulation
Product can queue along the line and be picked off as needed, which makes roller conveyors well suited to picking, packing and buffering between processes.
Low running cost
Gravity sections use no power at all, and powered sections can be zoned so that motors only run where product is present.
Easy to work along
Operators can reach across and work at any point on the line, and sections can be lifted out or hinged for access and walkways.
Sized to your product
Roller pitch, diameter and frame width are set from your smallest carton and your heaviest load rather than from a fixed catalogue size.
Reconfigurable
Straight runs, curves, gates and transfers connect together, and gravity sections can be moved as the layout changes.
Applications
- Warehouse and distribution handling
- Pick, pack and dispatch lines
- Loading and unloading bays
- Carton, tote and crate transfer
- Pallet handling and staging
- Accumulation and buffering between processes
- Assembly and inspection benches
- Goods-in and goods-out areas
Typical specifications
- Types
- Gravity (unpowered) and powered roller, including zero pressure accumulation
- Roller pitch
- Set so at least three rollers support the product at all times, typically no more than one third of the shortest product dimension
- Roller diameter
- Smaller diameters for light parcels, larger diameters for cartons, crates and pallets
- Roller materials
- Steel, stainless steel, galvanised or plastic depending on load and environment
- Frame
- Mild steel, galvanised or stainless steel for wash-down and damp areas
- Layouts
- Straight runs, curves, gates, spurs and transfer sections
- Load
- From light parcels through to full pallets, sized on the heaviest unit load
Typical values for this conveyor type. Final specifications are confirmed for your application on quotation.
Frequently asked questions
What is the difference between a gravity and a powered roller conveyor?
A gravity roller conveyor has no motor. Product is pushed by hand or runs down a slight fall, so there is no running cost and very little maintenance. A powered roller conveyor drives the rollers by motor for controlled, consistent movement, which is what you need for higher volumes, longer runs, inclines and automated lines.
What roller pitch do I need?
The product must be supported by at least three rollers at all times, otherwise it drops between them and stalls. As a working rule the pitch should be no more than one third of the shortest dimension of the smallest item you handle. We set the pitch from your smallest carton, not your average one.
What roller diameter should I use?
Diameter is chosen for load. Small diameter rollers suit light parcels and totes, medium diameters suit general cartons, and larger heavy-walled rollers are used for heavy cartons and pallets. Larger rollers carry more load but need a longer product to bridge across them properly.
Can a roller conveyor accumulate product?
Yes, and it is one of the main reasons to choose one. Product queues naturally along the line. Where items must not press against each other, zero pressure accumulation uses zoned rollers so each item stops in its own zone, which protects fragile product and prevents jams.
Can roller conveyors handle pallets?
Yes, using a heavy-duty pallet roller conveyor with larger diameter rollers, wider pitch and a reinforced frame. The conveyor is sized on your heaviest pallet load and the pallet base condition, since damaged or irregular pallet boards affect how they run.
Should I use a roller conveyor or a belt conveyor?
Use rollers for firm flat-based product such as cartons, totes, crates and pallets, especially where you need accumulation. Use a belt where product is small, light, unstable or has an uneven base, where it would fall between rollers, or where you need a continuous surface for inclines.