In modern warehousing, distribution, and manufacturing, pallet conveyors play a critical role in optimizing material handling. These large format conveyors are designed to move heavy, bulk goods quickly (but stable) across a warehouse or distribution facility, reducing manual labor and improving throughput. However, selecting the right type of pallet conveyor depends on the specific needs of an operation, such as load capacity, space constraints, product to be handled, and level of automation.
In this blog, Century will explore the different types of pallet conveyors, how they work, and when to use them in your facility for maximum efficiency.
Pallet Conveyor Equipment Types
Roller Pallet Conveyors
Roller pallet conveyors use a series of metal rollers to transport pallets. They can be either gravity-driven (where pallets move due to incline) or motorized (driven by chains or belts). This solution is the most commonly-integrated pallet conveyor equipment.
Key Features:
- Designed for handling heavy loads.
- Available in powered and non-powered variations.
- Can be customized for pallet size and load weight.
Best Use Cases:
- Accumulation: Ideal for buffering and staging pallets before loading or storage.
- Sorting & Distribution: Can integrate with scanning and sorting systems.
- Warehouse & Manufacturing Lines: Used for transporting pallets between different processing stations.
Use powered roller conveyors when you need controlled movement, and gravity rollers when cost-efficiency is a priority. Gravity works well for slower-moving ops and staging, powered should be used for continuous movement
Chain-Driven Pallet Conveyors
Chain pallet conveyors use chains to move pallets along a fixed path. These conveyors are highly durable and are built for heavy-duty applications. Simplicity in design make maintenance easy and supports slower, more stable operations.
Key Features:
- Suitable for handling non-standard or bottom-boarded pallets.
- Can handle heavier loads than roller conveyors.
- Offers precise pallet control, making them ideal for automated storage and retrieval systems (AS/RS).
Best Use Cases:
- Heavy Manufacturing: Great for industries like automotive, steel, and heavy equipment.
- Cold Storage: Operates well in extreme temperature conditions.
- High-Traffic Areas: Works well in high-volume facilities with heavy palletized loads.
Choose chain-driven conveyors when handling uneven, non-standard, or extra-heavy pallets.
Belt-Driven Pallet Conveyors
Belt-driven pallet conveyors use a continuous belt to transport pallets. These are often used in applications where smooth, gentle movement is required. Often seen as a seldom-integrated alternative to slow-moving gravity applications.
Key Features:
- Less vibration compared to roller conveyors.
- Can handle a variety of pallet sizes without modification.
- Suitable for delicate or sensitive loads.
Best Use Cases:
- Fragile Product Handling: Used in food, pharmaceuticals, and electronics industries.
- Incline/Decline Conveyance: Works well when moving pallets between floors or height levels.
- Light-to-Medium Loads: Best for applications that don’t require heavy-duty transportation.
Use belt-driven conveyors for products that require gentle handling and precise movement.
Drag Chain Pallet Conveyors
Drag chain conveyors use multiple segments of chain to pull pallets along a track. They are designed for applications where pallets need to be moved smoothly and at a consistent pace.
Key Features:
- Excellent for transferring pallets between different conveyor sections.
- Works with wooden, plastic, and metal pallets.
- Often used for 90-degree transfers in automated systems.
Best Use Cases:
- Pallet Transfer Systems: When integrating with robotic picking or AS/RS.
- Cross-Docking: Moving pallets quickly in a high-speed distribution center.
- Heavy Industrial Environments: Common in automotive and manufacturing sectors.
Use drag chain conveyors when handling diverse pallet types or when changing direction in a conveyor system.
Turntable Pallet Conveyors
Turntable pallet conveyors allow pallets to change direction while staying on the same conveyor path. These are often integrated with roller or chain conveyors. Other methods of diverting a pallet can come in the form of roller attachments on AGVs/AMRs or stacker systems that transport full pallets to a higher level (or stack empty pallets).
Key Features:
- Provides flexibility in warehouse layouts.
- Rotates pallets 90° or 180° to match different conveyor lines.
- Reduces the need for manual handling or forklift usage.
Best Use Cases:
- Space-Constrained Warehouses: Helps redirect pallets in small layouts.
- Multi-Directional Conveyor Systems: Used in complex sorting and fulfillment setups.
- Pallet Orientation Needs: When pallets need to be positioned before scanning, wrapping, or unloading.
Use turntable conveyors to improve flow efficiency in confined warehouse spaces.
Transfer Cars & Shuttle Conveyors
Transfer cars and shuttle conveyors allow pallets to be transported across different conveyor lines or multiple warehouse zones. These can come in the form of a simple gravity line, or a complex ASRS or mobile pallet robot system setup.
Key Features:
- Offers high-speed transportation across large distances.
- Works well in automated and high-throughput facilities.
- Can handle multiple pallet sizes simultaneously.
Best Use Cases:
- Large Warehouses & Distribution Centers: When moving pallets between different fulfillment zones.
- Automated Warehousing: Works in combination with robotic picking and AS/RS.
- Multi-Level Operations: Ideal for facilities with vertical storage systems.
Use transfer cars for high-volume, multi-zone material handling in large-scale logistics centers.
What Pallet Conveyor Equipment Type Fits My Needs?
Handling Specification | Recommended Pallet Conveyor Unit |
|---|---|
Heavy-Duty Loads | Chain-Driven, Drag Chain |
Light-to-Medium Loads | Roller, Belt-Driven |
Gentle Handling | Belt-Driven |
Cold Storage | Chain-Driven, Drag Chain |
High-Speed Transfer | Transfer Cars, Roller |
Limited Space | Turntable, Drag Chain |
Multi-Directional Flow | Turntable, Shuttle |
Pallet conveyors are essential for improving warehouse efficiency, reducing labor costs, and enhancing order fulfillment speed. By understanding the different types of pallet conveyors and their ideal use cases, businesses can design material handling systems that align with their operational needs.
Century Conveyor has completed a variety of pallet conveyor system projects spanning across the wide range of equipment types. Interested in a system? Contact a Century Automation Expert to start planning yours, or explore the range of solutions we can implement in your facility.
