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Belt vs. Roller Conveyors: Which is Best for Your Facility?

For many industry sectors, conveyor systems remain essential components to support streamlined material handling operations and increased efficiency needed for today’s logistics and manufacturing challenges. However, choosing the right option between belt and roller conveyors for your specific operational needs can be a daunting task. Each system offers unique benefits and features, and the most appropriate choice largely depends on your specific industry and individual operational needs. Conveyor systems play a crucial role in ensuring the transportation of products runs smoothly in various facilities.

L-A-C has been at the forefront of belt and roller conveyor innovation for nearly 30 years, designing and installing countless solutions to help support our customers’ current operations and continued growth. Our latest article explores the differences between types of conveyor systems, their industry-wide applications, the main features and benefits of each conveyor type, and the nine key factors to consider to help you decide which is the most appropriate solution for your facility.

Understanding Belt and Roller Conveyors

What are Belt Conveyors?

Belt conveyors use a continuous loop of material (usually rubber, fabric, or synthetic) to move items from one location to another. These systems are powered by electric motors and are often equipped with pulleys for smooth movement. Their flat conveyor belt design ensures that products remain stable during transport, particularly delicate materials or fragile loads.

What are Roller Conveyors?

Roller conveyors use a series of cylindrical rollers, usually manufactured using stainless steel, aluminium, or powder-coated materials. Roller conveyors are either powered or gravity-driven, to transport items quickly and efficiently. These systems are primary types of conveyors that are vital for handling heavier loads like pallets and large containers. They are modular, allowing easy customisation for different conveyor system designs.

Due to their modular design, both belt conveyors and roller conveyors can be combined and integrated with other types of conveyors and industrial equipment such as pallet roller conveyors, incline belts, tote stackers, or robotic palletisers. Collectively, these technologies offer a robust and fully automated conveyor system that optimises throughput and enhances safety with limited manual intervention required. Integration with chain conveyor systems or spiral conveyors can further enhance the system’s functionality for specific operational needs.

Applications Across Key Industry Sectors

line shaft powered roller conveyor system

Belt Conveyors

Retail

Belted conveyors are ideally suited for the transportation of products such as boxed or bagged goods in warehouses and distribution centres in the retail sector. Their consistent speed ensures a constant flow of goods, improving operational efficiency.

Roller conveyors are commonly used in sorting and packaging areas, where they can handle lighter loads and enable product redirection or accumulation. These conveyors are effective for managing load transfer and aiding warehouse staff by minimising manual handling of bags of materials or boxed goods.

Food and Beverage

Belt conveyor systems are an ideal option for material handling processes in the food sector, especially for delicate materials like unpackaged or loose products. Their flat surface ensures hygiene and ease of cleaning, making them perfect for pharmaceutical industries and other strict regulatory environments.

Roller conveyors are effective for applications with products such as bottled beverages or canned goods, providing additional stability for heavier loads in rigid containers like trays or totes.

Manufacturing

Flat conveyor belts are extensively used in manufacturing operations for transporting bulk materials or finished goods. They are essential for assembly lines requiring constant speed and smooth load accumulation. These conveyors can also handle a wide variety of materials and are suitable for sticky material or bulky items.

Roller conveyors, including types of roller conveyor systems, are better suited for heavier loads or items with a rigid base, such as metal parts or full-sized pallets. Their modular conveyor surface design is ideal for high-volume industrial environments.

Grocery

In the grocery sector, belt conveyor systems are frequently used for moving light loads or fragile products within storage facilities. Their smooth operation ensures the safe handling of bags of materials.

Roller conveyors, on the other hand, are utilised in sorting or packing areas to handle load transfer for crates, trays, and pallets. These systems are effective for product accumulation and managing product weight during transport.

Benefits and Technology Features

Belt Conveyors

Advantages

Belt conveyors are highly versatile and suitable for a range of items, including irregular-shaped products and delicate materials. They provide a continuous flow for long-distance transportation and can handle a wide variety of industries.
Their materials, such as rubber, make them easy to clean, crucial for industries like food and pharmaceuticals.
They operate at a constant speed, ensuring a vital role in efficient operations.

Technology Features

Continuous belt models include incline and decline options for space optimisation.
Variable speed controls allow adjustment for different operational needs.
Specialised belts, such as anti-static or heat-resistant types, enhance durability for various material handling processes.

Roller Conveyors

Advantages

Roller conveyors are cost-effective for initial investment and provide long-term adaptability due to their modular conveyor system designs.
They handle heavier loads with ease and offer sustainable options, like gravity conveyors, that require no power.
Robust and durable, they are ideal for load accumulation and separate product handling in logistics and manufacturing environments.

Technology Features

Motorised rollers and sensors enable smart sorting and accumulation.
Flexible configurations ensure efficient handling of fragile products and prevent product damage.

Factors to Consider When Choosing a Conveyor Solution

Type of Goods: Consider the size, shape, and fragility of items. Flat conveyor belts handle fragile loads well, while roller conveyors manage heavier loads.
Length of Transport: For long distances, belt conveyor systems ensure a continuous flow of goods. Roller conveyors are ideal for shorter, modular applications.
Facility Layout and Space Constraints: For complex layouts, roller conveyors’ flexible system configuration excels.
Operational and Energy Costs: Gravity conveyors reduce energy costs, while belted conveyors offer consistent performance for demanding applications.

Conclusion

Both belt and roller conveyors provide robust, reliable, and flexible solutions for today’s material handling systems, yet serve different purposes. Understanding your facility's specific needs and operational requirements is essential to make the right choice. By evaluating your goals and the demands of your sector, you can select a conveyor system that enhances efficiency and supports long-term growth.

L-A-C Logistics Automation is one of the UK’s leading systems integrators with nearly 30 years’ experience in designing, manufacturing, and implementing innovative conveyor system designs tailored to modern warehousing, manufacturing, and production needs. As the UK manufacturer of industry-leading conveyor modules and systems, we offer robust solutions with favourable lead times, alongside access to spares and accessories to support maintenance and future growth.

Start your journey by contacting our team of experts today.