Conveyor technology: which system fits cartons, totes and pallets?
Conveyor technology is the backbone of every automated facility – and yet it is often planned last. In reality, the load carrier determines the system, not the other way round.
- The load carrier (carton, tote, pallet) determines the right conveyor technology.
- Continuous conveyors are unbeatably cheap per unit under constant load.
- Plan interfaces and integration (fire protection, robots, AGVs) early.
Cartons: light but moody
Roller and belt conveyors are the standard. The devil is in the detail: varying quality, undersized boxes, soft bottoms. If you don't know your carton spectrum, you will see faults by the minute. A carton analysis before planning is mandatory.
Totes: automation's favourite
Defined dimensions, stable bottoms, stackable: totes are the most reliable load carrier for high dynamics – ideal with shuttle systems and goods-to-person picking. Choosing the tote (size, subdivision, volume) is a genuine planning decision.
Pallets: heavy business
Roller and chain conveyors, turntables, vertical lifts: pallet conveying is robust but needs space and load reserves. Pallet quality and overhangs are critical – one damaged carrier can shut down an entire line.
The overview
| Load carrier | Typical technology | Strength |
|---|---|---|
| Carton | Roller/belt conveyors, sorters | Direct dispatch flow |
| Tote | Tote conveyors, shuttle connection | High dynamics, goods-to-person |
| Pallet | Roller/chain conveyors, vertical lifts | Heavy loads, full pallets |
| Special solutions | Overhead conveyors, trays, custom carriers | Non-standard products |
Integration: more than steel and rollers
Conveying does not end at the transfer point. Fire protection closures, robot cells and AGV transfers must be part of layout and controls from the start – retrofitting integration is expensive and fault-prone.
Always size conveyors for the peak hour, not the daily average – and plan accumulation buffers ahead of every bottleneck.
Conveyor planning ahead?
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