Types of Conveyors: Options in Automation

Overview of Conveyor Systems

A conveyor system is a mechanical solution designed to transport materials from one point to another within a facility. These systems are integral to automation, offering streamlined, continuous movement of goods without the manual handling that slows productivity or introduces risk.

The benefits of implementing a conveyor system are numerous. They significantly improve operational efficiency by reducing travel time and human error. Labor costs drop as repetitive material handling tasks are automated. Additionally, conveyors enhance safety by reducing the need for workers to lift, carry, or maneuver heavy or awkward loads—especially over long distances or through complex facility layouts.

Whether you’re moving pallets, cartons, totes, or granular materials, the right conveyor system can become the backbone of your throughput strategy. Each type of conveyor offers unique advantages, and understanding these options is essential for building scalable, future-ready material handling operations.

Roller Conveyors
Roller conveyors use a series of cylindrical rollers to move products across horizontal or slightly inclined paths. These systems are especially effective for transporting rigid, flat-bottomed items such as cartons, bins, or totes. Their modular design makes them easy to integrate into a wide range of material handling systems.

There are several types of roller conveyors based on how the rollers are powered:

• Gravity roller conveyors rely on the force of gravity and are best suited for manual push zones or areas with a decline.
• Powered roller conveyors use motors to drive the rollers and enable consistent flow, even on flat terrain.
• Line shaft conveyors use a single shaft powered by an electric motor to rotate multiple rollers via spools and bands.
• Motor-driven roller (MDR) conveyors feature individual motors in select rollers, offering precise control, reduced noise, and energy efficiency.

Roller conveyors are a key component in many warehouse automation systems due to their flexibility and ability to handle various product types without complex customization. Their scalability and modularity also make them a natural fit for phased implementation strategies.

Chain Conveyors

Chain conveyors are built for strength and durability, making them ideal for moving heavy, bulky, or hot items through production environments. They use chains—often in dual-strand or multi-strand configurations—to pull products along a fixed path. This design delivers powerful, precise movement, even under extreme industrial conditions.

These systems are widely used in sectors such as metalworking, manufacturing, and the automotive aftermarket, where traditional roller or belt conveyors may not withstand the operational demands.

In addition to their durability, chain conveyors provide:

• Excellent load control for items that are too heavy or irregularly shaped for belts or rollers.
• Heat resistance in applications where hot components or materials are handled.
• Customization to accommodate fixtures or carriers that secure parts in position during transport.
• Chain conveyors are often essential for environments where precision, strength, and continuous throughput are non-negotiable.
  
  

Overhead Conveyors

Overhead conveyors are suspended systems designed to transport products above the main working floor. This frees up valuable ground space, enabling operations to continue below while material moves continuously overhead. These systems are commonly found in automotive assembly lines, paint shops, and garment manufacturing—especially where clean, obstruction-free floors are critical.

Overhead systems come in several types, including:

• Enclosed track conveyors, which provide a compact, clean solution with minimal exposure to the environment.
• Power and free conveyors, which allow for controlled stops, accumulation, and routing of products on independent tracks.

• Space optimization is essential due to floor congestion or limited square footage.
• Process sequencing and product accumulation are required for multi-stage production or curing lines.
• Hanging transport is necessary to protect sensitive or freshly painted items.

Pneumatic and Vacuum Conveyors

Pneumatic and vacuum conveyors are advanced material handling systems that use air pressure or suction to transport products through enclosed pipelines. These systems are especially effective for moving fine powders, granules, and lightweight bulk materials—ideal in industries that demand sanitary, dust-free handling such as pharmaceuticals, food processing, and chemicals.

By creating airflow within sealed tubes, these conveyors gently carry materials from one point to another with minimal degradation or contamination. This is particularly important in sensitive sectors like pharmaceutical and life sciences, where hygiene and material integrity are top priorities.

Benefits include:

• Enclosed transfer systems that prevent dust emissions and exposure to external contaminants.
• Reduced product loss due to careful handling of fragile or fine materials.
• Flexible routing over long distances and around complex layouts.
  
  These systems not only improve cleanliness and product protection but also support regulatory compliance and efficiency in high-purity environments.
  
  

Screw (Auger) Conveyors

Screw conveyors, also known as auger conveyors, use a rotating helical screw blade housed within a tube or trough to move materials. This continuous rotation propels bulk materials forward in a controlled, metered flow, making them ideal for handling semi-solid materials, powders, grains, and food waste.

You’ll commonly find screw conveyors in agricultural, food processing, and wastewater treatment applications due to their simplicity and efficiency in transporting materials that aren’t suitable for belts or rollers. Their enclosed design also minimizes dust and protects material integrity.
Screw conveyors are particularly well-suited for:

• Horizontal and inclined transport of consistent flow materials.
• Controlled discharge with precise volumetric feeding.
• Applications involving mixing or blending as part of the conveying action.
  
  They’re an essential part of systems requiring a robust, low-maintenance solution for conveying viscous or granular materials across short to moderate distances.
  

Slat Conveyors

Slat conveyors are built with slats—flat plates or panels—attached to chains, providing a robust and stable surface for transporting heavy, hot, or irregularly shaped items that might damage belts or rollers. The design allows for precise movement and easy handling of challenging products across production environments.

These conveyors are frequently found in manufacturing, bottling, and automotive lines, where durability and positive traction are essential. Unlike belt conveyors, slat conveyors can carry materials with sharp edges, abrasive surfaces, or non-uniform shapes without slippage or belt wear.

Key advantages of slat conveyors include:

• Reliable transport of awkward items not suited for traditional conveyor types.
• High load-carrying capacity without product shifting or falling.
• Customizable slat surfaces (e.g., metal, plastic, or rubber-coated) to suit specific handling needs.
  Their versatility and strength make them a preferred choice for continuous flow operations where product orientation and stability are critical.
  
  
  
  

Spiral Conveyors

Spiral conveyors offer a smart vertical solution for operations looking to maximize floor space while maintaining continuous product flow between different elevations. These conveyors move items in a spiral path, enabling high throughput in a compact footprint.

They are widely used in packaging, e-commerce, and distribution centers where goods must be moved efficiently between mezzanines, floor levels, or different processing zones. Their ability to handle a variety of product sizes makes them ideal for high-volume, mixed SKU environments.

Notable advantages of spiral conveyors include:

• Space-saving vertical transport without interrupting the product stream.
• Gentle handling of goods, reducing product damage.
• Continuous flow, reducing bottlenecks compared to lifts or vertical reciprocating conveyors.
  
  Spiral conveyors are a go-to choice for operations prioritizing both efficiency and space optimization.

Modular Plastic Belt Conveyors

Modular plastic belt conveyors are built for durability, flexibility, and hygiene, making them a staple in environments requiring frequent washdowns or product changes. These systems use interlocking plastic modules instead of a continuous belt, allowing for easy customization and replacement of sections without halting operations.

They’re especially common in food processing, pharmaceuticals, and cleanroom environments, where cleanliness and corrosion resistance are non-negotiable. The plastic material resists chemical damage and is easier to sanitize compared to traditional belts.

Key advantages of modular plastic belt conveyors include:

• Tool-less maintenance and quick repairs with snap-in modules.
• Superior drainage and open-hinge designs for easy cleaning.
• Custom layouts, including curves, inclines, and declines, without compromising reliability.
• Their combination of hygiene, modularity, and toughness makes them an essential component in high-compliance, high-throughput operations.

Magnetic Conveyors

Magnetic conveyors are specialized systems designed to move ferrous materials—such as steel components, metal filings, or scrap—using integrated magnets beneath or within the conveyor surface. These systems are widely used in metalworking, recycling, and manufacturing environments where traditional conveyor types struggle with slick or loose materials.

The embedded magnetic field securely holds the product in place as it moves through the conveyor path, even along inclines or upside-down sections. This helps prevent spillage, contamination, or misalignment during transit.

Notable benefits of magnetic conveyors include:

• Enclosed systems that reduce mess and improve safety.
• Precise handling of sharp or irregular metal items without jamming.
• Integration flexibility with other automation systems.
  
  In industries with ferrous materials and high cleanliness requirements, magnetic conveyors offer a secure and efficient way to transport product while protecting workers and equipment

Bucket Elevators

Bucket elevators are vertical conveying systems designed to move bulk materials such as grains, powders, or fertilizer by using a series of buckets attached to a belt or chain. These buckets scoop material from a lower level and discharge it at a higher elevation, making them ideal for applications where space is limited, but vertical movement is essential.

They are commonly found in industries like agriculture, mining, pharmaceuticals, and industrial manufacturing, where large volumes of product must be lifted vertically with minimal product degradation.

Key features include:

• Gentle handling of fragile or dusty materials.
• Fully enclosed designs that help prevent contamination and spillage.
• Custom bucket sizes and discharge options to accommodate a wide range of materials and flow rates.
  
  For operations requiring vertical lifts with minimal floor space and controlled material flow, bucket elevators are a reliable and scalable solution.
  
  
  

How to Choose the Right Conveyor

Selecting the right conveyor system is a critical decision that affects operational efficiency, safety, and long-term costs. The ideal conveyor must match your specific product characteristics and throughput goals while fitting within the constraints of your facility.

Key factors to consider include:

• Product Characteristics: Consider the weight, fragility, size, and material of your products. For instance, fragile items may be better suited for vibrating conveyors, while heavy-duty chain conveyors are ideal for industrial components.
• Throughput and Speed Requirements: Facilities with high-speed operations or continuous product flow may benefit from spiral conveyors or MDR systems that can handle variable speeds.
• Layout and Space Constraints: Overhead conveyors and spiral systems can help preserve floor space, while modular systems provide flexibility for layout changes over time.
• Cleanliness and Maintenance: Environments such as food processing or pharmaceuticals require easy-to-clean systems like modular plastic belt conveyors or pneumatic conveyors that reduce contamination risks.
• Automation and Integration Needs: Facilities focused on warehouse automation should evaluate how the chosen conveyor integrates with other systems like WES, WCS, or robotics. Maveneer’s approach to warehouse automation and systems integration ensures that conveyors are part of a scalable, future-proofed solution.

With proper selection and design, conveyors can do more than move goods—they can transform your entire operation.

Conclusion

Conveyor systems are essential to any modern warehouse or manufacturing environment, and the range of available conveyor types allows operators to tailor solutions to their unique operational challenges. From belt and roller conveyors to highly specialized systems like vacuum or magnetic conveyors, each type plays a distinct role in improving efficiency, safety, and scalability.

Whether your goal is to increase throughput, reduce labor costs, or integrate seamlessly with broader warehouse automation strategies, the right conveyor selection is key. Evaluating your layout, products, and long-term goals ensures you choose a system that will grow with your operation.

If you’re planning a conveyor upgrade or building from the ground up, Automation as a Service from Maveneer provides the engineering, integration, and ongoing support needed to deliver a smart, future-ready solution