Leading Roller Conveyor Manufacturers

What is a Roller Conveyor?

A roller conveyor is a fundamental material handling solution designed to transport a wide range of products efficiently within warehouses, distribution centers, manufacturing plants, and logistics hubs. Roller conveyors consist of a sequence of cylindrical rollers mounted within a sturdy frame, allowing goods—such as cardboard boxes, pallets, crates, plastic totes, polybags, trays, and slave boards—to move either manually, by powered mechanisms, or via gravity.

Roller conveyor systems can be customized and integrated with ancillary equipment, such as bends, turntables, and gates, making them highly adaptable for various industrial applications. Their modularity and versatility make roller conveyors one of the most widely used conveyor types in the material handling equipment (MHE) industry.

Looking to optimize your facility’s throughput? Explore how roller conveyors can improve workflow, reduce manual labor, and boost order fulfillment speed by streamlining the movement of goods across your operation.

How a Roller Conveyor is Made

Roller conveyor construction relies on several key components, each engineered for durability, efficiency, and flexibility. Understanding the anatomy of a roller conveyor is crucial whether you are specifying a new system, upgrading existing equipment, or troubleshooting for optimal performance.

Rollers for Roller Conveyors

The core of any roller conveyor is its rollers—cylindrical components typically made from steel, stainless steel, aluminum, or nylon. Each roller is mounted on a shaft with precision bearings, enabling smooth rotation under varying loads. The roller material and diameter are selected based on load capacity, environmental conditions, and application requirements. For example, stainless steel rollers are ideal for food-grade or washdown environments, while heavy-duty steel rollers excel in pallet handling and bulk material transport.

Curious about roller selection? Discover which roller type is best for your application—consider load weight, speed, environmental exposure, and whether you need accumulation or non-accumulation zones.

Motor for Roller Conveyors

Powering the movement of products, roller conveyors may use AC induction motors, DC motors, stepper motors, or servo motors. AC induction motors are popular for continuous, unidirectional operation, while synchronous motors are selected for applications requiring precise timing. DC motors and brushless motors are frequently used in modern motor-driven roller (MDR) conveyors for zone control and energy efficiency.

Where variable speed, torque control, or high-precision positioning are required, stepper motors or servo motors are implemented. Advanced smart motors can also integrate with programmable logic controllers (PLCs) or warehouse control systems (WCS) for automated material handling.

Need to choose between powered and gravity rollers? Evaluate your throughput, product type, and automation level to determine if a powered roller conveyor or a gravity conveyor is right for your application.

Structure and Legs for Roller Conveyors

The structural frame and support legs are designed for stability, load-bearing capacity, and adaptability. Most frames are constructed of powder-coated or galvanized steel for corrosion resistance and strength. Adjustable-height legs and modular side rails make installation flexible, supporting integration with mezzanines, loading docks, or other conveyor systems.

Want to maximize conveyor life? Ensure your conveyor structure is built to handle your heaviest loads and is compliant with safety and ergonomic standards.

Non Precision Bearings for Roller Conveyors

Bearings are critical for smooth rotation and minimal maintenance. Two main types of ball bearings used in roller conveyors are:

• Angular Contact Ball Bearings

  These bearings are engineered to support combined axial and radial loads, making them suitable for high-speed conveyor applications and environments where both thrust and radial forces are present. Angular contact ball bearings are typically arranged in pairs for optimal load distribution.

• Pillow Block Bearing

  Pillow block bearings, or plummer blocks, are mounted pedestals that provide support for rotating shafts with compatible cartridge inserts. Their robust cast iron or steel housings are ideal for heavy-duty and high-load conveyor systems, commonly found in the food and beverage, mining, and bulk material industries.

Sprockets for Roller Conveyors

Sprockets are toothed wheels or gears that transmit rotary motion from a drive mechanism to the rollers, often via chains. Sprocket-driven conveyors offer positive drive and are commonly used for pallet handling, automotive assembly lines, and applications requiring synchronization between rollers.

Wondering about drive options for roller conveyors? Compare chain, belt, and line shaft drives to determine which best suits your load type, speed, and maintenance requirements.

Types of Roller Conveyors

The diversity of roller conveyor types allows for tailored solutions that address specific material handling challenges. The main types of roller conveyors include:

Gravity Roller Conveyor

Gravity roller conveyors utilize the force of gravity, enabling items to move passively without external power. These conveyors are cost-effective, low-maintenance, and ideal for flat-bottomed goods, order picking, assembly lines, and warehouse transfer areas. They are commonly found in packaging, shipping, and receiving operations.

Belt Driven Roller Conveyor

Belt-driven roller conveyors use a continuous belt to drive rollers, making them suitable for the transport of irregularly shaped or fragile items. These systems operate quietly and reliably, even at high speeds, and are frequently used for sorting, merging, and accumulation in distribution centers and e-commerce fulfillment facilities.

Chain Driven Roller Conveyor

Chain driven roller conveyors are engineered for heavy-duty applications, such as moving pallets, drums, and other large unit loads. Chains transmit power to each roller, ensuring positive drive and high throughput, even in demanding industrial environments. Integrate with pop-up transfers or turntables for multidirectional flow and flexible layout design.

Line Shaft Roller Conveyor

Line shaft roller conveyors employ a rotating shaft running beneath the rollers, using spools and elastic belts to transfer motion. These conveyors are ideal for light to medium loads—like tote boxes and cartons—offering quiet operation, easy assembly, and flexibility for curves and merges. They are popular in distribution centers and light manufacturing.

Powered Roller Conveyors

Powered roller conveyors (also known as motorized roller conveyors or MDR conveyors) use individual or zoned motors to drive rollers, providing precise control for accumulation, sorting, and routing. Each conveyor zone can be independently controlled, enabling zero-pressure accumulation and gentle handling of fragile or sensitive products. These conveyors are key in automated warehouse systems, e-commerce, and parcel distribution.

Motor Driven Live Roller (MDLR)

Motor Driven Live Roller conveyors are a newer innovation in conveyor technology. They utilize distributed, low-voltage DC motors, often built directly into the roller, to create individually controlled accumulation zones. MDLR systems offer energy efficiency, modularity, and advanced integration with sensors and controls, making them ideal for automated handling of totes, cartons, and order fulfillment.

Other Specialized Roller Conveyor Solutions

Specialized roller conveyor designs address unique challenges such as:

• Flexible or expandable roller conveyors for loading/unloading trucks and temporary workstations.
• Accumulation roller conveyors with sensors for buffering products before downstream processes.
• Incline and decline roller conveyors for elevation changes between levels or mezzanines.
• Stainless steel roller conveyors for sanitary or corrosive environments.

Searching for a custom conveyor solution? Connect with a roller conveyor manufacturer to discuss your unique facility layout, product mix, and throughput goals.

Applications of Roller Conveyors

Roller conveyors are a staple in a wide range of industries due to their flexibility, scalability, and efficiency. Common roller conveyor applications include:

• Manufacturing and Assembly Lines: Automate product movement, reduce manual handling, and increase productivity in automotive, electronics, and appliance production.
• Food Handling: Convey packaged goods and ingredients with sanitary designs and food-grade materials to maintain hygiene standards.
• Mail and Parcel Delivery Services: Accelerate sorting and distribution of packages and envelopes in postal and courier facilities.
• Baggage Handling: Transport luggage efficiently within airports, reducing wait times and improving passenger experience.
• Steelmaking and Heavy Industry: Move coils, billets, and heavy components within foundries and metal fabrication plants.
• Packaging & Order Fulfillment: Streamline picking, packing, and shipping in e-commerce, wholesale, and retail logistics operations.
• Logistics and Warehousing: Facilitate cross-docking, goods receiving, and inventory management with scalable conveyor solutions.

Not sure if roller conveyors will work in your industry? Contact a conveyor systems expert to discuss industry-specific use cases and compliance requirements.

Benefits of Roller Conveyor Systems

Investing in a roller conveyor system brings several compelling advantages:

• Increased Efficiency: Reduce manual transport, streamline workflows, and minimize bottlenecks.
• Labor Savings: Lower labor costs and decrease the risk of workplace injuries associated with manual lifting and carrying.
• Scalability: Modular designs enable easy expansion or reconfiguration as your business grows.
• Versatility: Handle a broad range of product sizes, shapes, and weights, from small cartons to heavy pallets.
• Low Maintenance: Simple design and robust construction reduce downtime and maintenance expenses.
• Energy Savings: Gravity and zone-powered systems minimize energy consumption compared to traditional conveyors.
• Integration: Easily interface with automated storage and retrieval systems (AS/RS), robotics, and sortation technologies.

Want to maximize your ROI on material handling investments? Learn how roller conveyor systems can be tailored for your business goals and facility constraints.

How to Select the Right Roller Conveyor

Selecting the optimal roller conveyor system requires a careful analysis of your operational needs, facility layout, and product characteristics. Key considerations include:

Material Characteristics

Assess the size, weight, shape, and surface of the items you need to convey. For heavy loads or pallets, choose reinforced rollers and frames; for small or delicate products, consider close roller centers and softer roller coverings. Understanding these factors ensures proper roller spacing, frame width, and drive selection.

Production Rate and Accumulation Choice

Define your throughput requirements—how many units per hour must the system handle? This will determine conveyor speed, drive power, and whether you need accumulation zones for buffering products before downstream operations.

Conveying Requirements

Consider the distance, elevation changes, and integration points with other equipment (such as packaging machines, palletizers, or sorters). Factoring in these requirements will help you choose between straight, curved, or incline/decline roller conveyor modules.

Environmental Conditions

Evaluate exposure to temperature extremes, humidity, dust, chemicals, or washdown conditions. Stainless steel or galvanized components may be necessary in corrosive or sanitary environments, while sealed bearings and covers protect systems in dusty or outdoor settings.

Safety and Ergonomics

Ensure compliance with industry safety standards—such as OSHA, ANSI, or CE. Incorporate features like side guards, emergency stops, and ergonomic heights to reduce risks and improve operator comfort.

Budget and Lifecycle Costs

Consider total cost of ownership—not just initial purchase price, but also installation, energy consumption, maintenance, and upgradeability. Modular systems may have a higher upfront cost but pay off in flexibility and scalability.

Have questions about selecting a conveyor system? Use our conveyor selection guide or reach out to our engineering team for a detailed assessment tailored to your operation.

Key Decision Factors When Purchasing Roller Conveyors

Making an informed purchase involves comparing roller conveyor suppliers, evaluating product specifications, and assessing after-sales support. Here’s what to consider:

• Supplier Reputation and Experience: Choose manufacturers with proven track records in your industry and positive customer testimonials.
• Customization Options: Ensure the supplier can tailor conveyor dimensions, roller materials, and drive types to match your specific needs.
• Delivery and Installation Support: Look for companies offering on-site installation, commissioning, and training services.
• Maintenance and Spare Parts: Ask about availability of replacement rollers, bearings, and motors, as well as preventive maintenance programs.
• Warranty and Service Agreements: Review warranty terms and post-installation support to minimize downtime and protect your investment.
• Integration Capabilities: Check compatibility with your existing material handling systems, automation controls, and software.
• Safety Compliance: Verify that all equipment meets relevant safety and regulatory standards.

Ready to compare roller conveyor suppliers? Use our directory of leading roller conveyor companies to request quotes, review technical capabilities, and preview websites before making your choice.

Choosing the Proper Roller Conveyors Supplier

To ensure a successful roller conveyor purchase, compare at least four or five qualified suppliers using our comprehensive list of roller conveyor companies. Each supplier profile includes detailed information about their experience, capabilities, and product offerings. Use our interactive tools to preview websites, access technical documents, and submit RFQ (Request for Quote) forms directly to manufacturers for competitive pricing and lead times.

Looking to streamline your procurement process? Take advantage of our multi-quote RFQ form to contact multiple roller conveyor manufacturers simultaneously, saving you time and helping you secure the best value on your next project.

Frequently Asked Questions About Roller Conveyors

• How do I determine the right roller diameter and spacing? Assess your product dimensions, weight, and the smallest item to be conveyed. This ensures stable transport and prevents jamming or product damage.
• What maintenance is required for roller conveyors? Regular inspection, lubrication of bearings, and prompt replacement of worn rollers or belts will maximize system uptime and longevity.
• Can roller conveyors be automated? Yes, powered and MDR conveyors can integrate with sensors, controls, and warehouse management systems for automated product movement and tracking.
• Are roller conveyors suitable for outdoor use? Select galvanized or stainless steel rollers and frames with weather-resistant bearings for reliable outdoor operation.
• What safety features should I look for? Key features include side guards, emergency stops, interlocks, and compliance with OSHA or CE standards.

Still have questions? Contact our conveyor experts for personalized recommendations or a free site assessment.