How Do Conveyor Systems Reduce Labour Costs in Material Handling

Logistics operations remain under strain due in part to the meteoric rise in online shopping in recent years. Consequently, handling the storage, picking, packing, and shipping processes for vastly increased volumes and complexity of goods with an uncertain supply chain has thrown up some ‘not-unexpected’ challenges. To help meet this demand, conveyor systems have become a vital part of modern warehouse infrastructure, enabling the efficient movement of goods through different stages of fulfilment. These systems play a key role in streamlining operations, supporting scalability, and reducing manual handling across facilities.

As efficiency, accuracy, safety, and sustainability all contribute to the success of a business, relying solely on manual processes is no longer a viable option for warehouse and distribution centre operations in the UK. Labour costs pose a significant challenge, with rising wages, a dwindling pool of available skilled labour, and increased demand for faster order fulfilment driving the need for more efficient solutions. Using workers for routine tasks such as material handling is labour-intensive, increases the risk of workplace injuries, and leads to inefficiencies in operations. Additionally, manual tasks introduce a higher likelihood of errors, such as entry errors and misplacements, impacting inventory management and overall efficiency. As a result, businesses are seeking automation tools to reduce the reliance on human intervention and improve productivity.

How Conveyor Systems Help Overcome These Challenges

Widely seen as the founding father of automated handling operations, conveyor systems address labour cost challenges by automating the movement of goods within a facility, significantly reducing the need for human interaction in repetitive tasks. This results in:

a conveyor as a conveyor systems warehouse

bespoke conveyors, conveyor system line

Reduced Workforce Requirements

Fewer employees are needed to transport items, lowering payroll expenses, the cost and need for training & onboarding, and lost productivity due to sickness. Humans also need comfortable working conditions, such as ambient temperature and good lighting, which contribute to operational costs.

Increased Efficiency

Automated systems work faster and more consistently than human workers. They use workflow automation software, sensors, and robotic integration to carry out essential tasks such as guiding, tracking, transporting, picking, and packing with accuracy, efficiency, and minimal downtime.

Lower Injury Rates

Reducing human tasks involved in lifting and carrying minimises workplace injuries and associated costs. Heavy or awkward items can cause strain-related injuries, reducing productivity and resulting in long-term absence.

Improved Accuracy

Conveyor systems help streamline operations by reducing human error, minimising costly rework, and enhancing quality control. As accuracy is vital for efficiency, conveyor systems and other automation technologies provide a robust and reliable solution to warehouse handling tasks, eliminating the risk of entry errors caused by humans.

Scalability

Businesses using conveyor systems can expand operations without a proportional increase in labour costs. They can rely on agile, modular automation equipment rather than manual processes, eliminating the need for costly staff recruitment and training at short notice. As conveyor systems are designed to handle an increased volume of goods quickly and efficiently with minor adjustments to the Warehouse Control System, businesses can benefit from scalability, which is pivotal in supporting streamlined operations and long-term business growth.

Types of Conveyor Systems and Their Applications

Conveyor system technology has evolved and adapted significantly over time, offering a wide range of conveyor systems to support business processes across different industries. These reduce the cost and need for manual labour for repetitive tasks. Some of the most common types of conveyors found in today’s logistics operations include:

roller conveyor

Roller Conveyors

Roller Conveyors are ideal for handling packages and pallets in distribution centres and assembly lines. They can be powered or gravity-fed to minimise energy usage.

Belt Conveyors

Belt Conveyors are used in warehouses, e-commerce fulfilment centres, and manufacturing to transport goods over long distances. They are suitable for items of varying sizes and weights.

Overhead Conveyors

Common in automotive and garment industries for moving products above ground level, optimising the available space.

Flexible Conveyors

Suitable for dynamic warehouse environments, offering easy reconfiguration based on needs. These are ideal for managing dynamic product ranges and fluctuations in order volumes.

Pneumatic Conveyors

Primarily used in food processing and pharmaceutical industries for transporting fine materials such as grains, flour, or delicate medical items.

Integration with Automation and Robotics

Without a doubt, the widespread implementation of conveyor systems to replace manual tasks provides a flexible and robust solution to material handling. Taking this a step further and integrating conveyor systems with other automation tools - such as robotics - provides superior levels of efficiency and accuracy in warehouse operations through fully automated solutions, further reducing the need for human intervention. Robotics can be deployed for tasks such as picking, packing, and palletising, working in harmony with conveyor systems to streamline the flow of goods. Here are just some of the advanced automation technologies that integrate seamlessly with conveyor systems in a warehouse environment:

Robotics

PALLETISING

Automated Guided Vehicles (AGVs)

AGVs transport goods within warehouses, reducing reliance on human interaction. They operate using sensors and programmed routes, ensuring efficient material movement while avoiding obstacles. AGVs enhance operational safety and help reduce bottlenecks in warehouse workflows.

Autonomous Mobile Robots (AMRs)

Unlike AGVs, AMRs are equipped with advanced navigation and AI-driven decision-making capabilities, making them highly adaptable. AMRs improve flexibility in warehouse operations, particularly for critical tasks such as Goods-to-Person operations, enhancing order accuracy and efficiency.

Robotic Pickers

These robotic arms use artificial intelligence and vision systems to identify, pick and place items onto conveyor belts. They eliminate human intervention in sorting and fulfilment tasks while increasing order accuracy and processing speed. Robotic pickers are particularly beneficial for inventory management and product quality control in e-commerce and retail distribution centres.

Palletisers

Automated palletisers stack and organise products onto pallets for shipping or storage. These systems reduce manual lifting and improve load stability, making them ideal for industries that require bulk product handling, such as food and beverage, pharmaceuticals, and manufacturing. De-palletisers, conversely, streamline operations by unstacking goods for onward distribution.

Sortation Systems

These automated systems use barcodes, RFID tags, or weight-based sorting mechanisms to direct items to their respective destinations at high speed. By automating this essential task, warehouses can handle higher order volumes with greater accuracy and efficiency, reducing human error and manual labour costs.

Warehouse Management Systems (WMS)

These software-driven solutions optimise inventory tracking, conveyor routes, and order fulfilment processes. WMS ensures seamless communication between conveyor systems and other automation technologies, providing valuable insights that support informed decisions and long-term cost savings.

Conveyor systems play a pivotal role in reducing labour costs in material handling by increasing efficiency, accuracy, and productivity while reducing reliance on human task execution and improving overall workplace safety.

The integration of conveyor systems with automation technologies such as AMRs, robotic pickers, and palletisers further enhances streamlined operations, minimising human intervention in repetitive and manual processes. This shift enables businesses to focus their workforce on high-value activities, strategic activities, and job satisfaction, ensuring competitive advantage in the modern logistics landscape while maintaining product quality and customer satisfaction.