Summary
Material handling conveyors streamline FMCG packaging operations by connecting filling, weighing, and palletizing processes while reducing manual handling. This blog covers conveyor types, applications, technical specifications, and key factors for selecting the right system.
Make product movement faster and smoother with the right conveyor system.
In FMCG plants, the work does not end when a pack is sealed. Snack packets, shampoo bottles, detergent pouches and beverage multipacks still have to be grouped, packed into cases, sealed and sent on. This secondary packaging stage is where many lines slow down.
These issues are quite evident. First, packs are manually shifted from machine to machine. Second, cartons build up in front of the case packer if one machine is running faster than another. Third, packs tend to become scratched or crushed during shifting. Finally, because of frequent changes of SKUs, adjustments need to be made often to handle various sizes of packs and cases.
A properly designed conveyor for material handling links the grouping process, case packing process, case sealing process, and the inspection process into a single flow. This is not meant to eliminate all bottlenecks; however, it may decrease manual handling, increase efficiency in the movement of products, and prevent any package damage. This blog highlights the types of conveyors, selection, and their use in FMCG secondary packaging lines.
What is a Material Handling Conveyor in FMCG Manufacturing?
In secondary packaging, a material handling conveyor carries sealed packs, bundles, cartons, cases and crates between machines. It starts once the primary pack is sealed and moves products through grouping, case packing and case sealing. After that it carries filled cases to inspection stations and on toward palletizing.
In the FMCG manufacturing industry, however, conveyors serve many more functions than simply transporting loads from one place to another. These machines are engineered to handle sorting hundreds of product sizes, operating at fast speeds, and preventing collisions of delicate packages. They connect the packaging machinery, including pouch filler machines and bagging machines, with the case packing machines, weight checkers, robotic palletizer, and loading dock areas.
How Does an Automatic Conveyor System Function in Packaging Lines?
The automatic conveyor system functions with the help of a roller system, photoelectric sensors, and some simple smart controllers. All these components ensure that goods move at the right speed and distance without any human intervention.
- Product Spacing: The belt makes spacing for the products which allows sensors and checkers to inspect them properly.
- Avoiding Damage to the Products: The products are kept in separate zones on the conveyor belt. This ensures that the products do not press against each other or crush each other.
- Separate Products Rapidly: The system ensures that the products move into the respective lanes.
- Supply Products To Palletising Stations: The conveyor transports boxes and bags at a constant speed, ensuring a consistent flow during the loading process.
Key Types of Automatic Conveyor Systems for FMCG
Various products require different conveyor belts and rollers in order to move safely.
Roller Conveyor Systems
Roller conveyors are suitable for solid objects having a flat surface, such as corrugated cardboard boxes, plastic containers, and heavy pallets.
- Live Roller Conveyors: The operation of these rollers relies on chains or belt-driven motors. They carry heavy boxes and cases for longer distances within a factory.
- Motorized Driven Roller (MDR) Conveyors: There are 24V DC motors in the rollers which drive the movement of the parcels only when necessary.
Modular and Flat Belt Conveyor Systems
Belt conveyors systems are suitable for soft pouches, small packages, or objects that may get stuck between the rollers.
- Plastic Modular Belts: Easily cleaned, which makes them suitable for use in food, dairy, and beverage applications.
- High-Grip Incline Belts: Assist bags and boxes travel up steep inclines without slipping.
Heavy-Duty Bag Conveyors
Where FMCG lines pack into bags, such as detergent powder or bagged household products, a bag conveyor keeps filled bags stable between machines.
- Side rails and belt supports help hold bags steady in transit.
- Flattening sections can help bags sit more evenly before case packing or palletizing.
Applications Across FMCG Secondary Packaging
Secondary packaging conveyors are used across many FMCG categories. The packs differ, but the aim is the same: steady flow with less handling and damage:
| FMCG Sector | Sealed Packs Handled | Conveyor Function | Realistic Line Benefit |
| Packaged Foods | Sealed snack packets, biscuit packs, food pouches | Belt conveyors feeding grouping and case packing | Smoother feed to the case packer, less scuffing of packs |
| Beverages | Multipacks, shrink-wrapped bottle packs, cartons | Roller and belt conveyors with accumulation before case packers | Controlled spacing and a buffer during short stops |
| Personal Care | Bottles, tubes, small cartons | Belt conveyors with accumulation sections | Helps keep lightweight packs upright and reduces label scuffing |
| Cosmetics | Small cartons, boxed products, gift packs | Gentle-handling belts feeding case packers | Less handling of delicate packaging |
| Home Care and Detergents | Detergent pouches, jugs, bagged products | Bag conveyors and roller conveyors for cases | Steady movement of heavier packs and filled cases |
Factors to Consider Before Choosing a Material Handling Conveyor
The decision about which type of conveyor to use depends largely on knowing your materials and the environment where you operate. There are some basic considerations that can assist you in making your decision.
- Production Speed: Select a conveyor system that can accommodate your fastest production rate. This will ensure that products are continuously in motion.
- Product Size and Weight: Ensure that your conveyor system is capable of handling the size and weight of your products, either light bags or 50 kg bags.
- Accumulation Requirements: Choose zero pressure accumulation so that no product is crushed by other products.
- Hygiene & Sanitation: Food production facilities should have easily cleanable conveyors. This could be stainless steel frames with food grade plastic belts.
- Footprint: Apply vertical rises, sharp turns, and overhead configurations in order to get maximum use of the floor area.
- Automation: Choose drives and sensors that work with your control system.
Technical Specifications: Intralogistic Conveyors
Instead of fixed technical parameters, these points will assist you in choosing a conveyor matching your line. The capacity and load weight are determined by the type of the conveyor and your requirements; therefore, specify them for your packs.
| Criterion | What to Check | Why It Matters |
| Pack size | Smallest and largest pack, bundle or case | Decides belt width, guide spacing and roller pitch |
| Weight | Lightest and heaviest item, including filled cases | Affects drive size, frame strength and belt or roller choice |
| Stability | Whether packs tip, slide or catch on rollers | Decides belt surface, guides and curve design |
| Throughput | Packs or cases per minute at peak speed | Sets conveyor speed and accumulation length |
| Layout | Floor space, machine positions, heights | Affects conveyor path, inclines and transfer points |
| Changeover needs | How often pack and case sizes change | Decides how adjustable the guides and settings need to be |
How Alligator Automations Serves FMCG Packaging Lines
Alligator Automations manufactures conveyors suitable for FMCG packing lines. The conveyors are functional, dependable, and designed to be operated at a very fast pace. Alligator Automations uses advanced laser cutting machines supplied by Bystronic and TRUMPF. The company employs clean and energy-efficient controls. Thus, it develops expandable conveyor systems.
- Full Range of Equipment: From quiet roller conveyors and sanitary plastic belt conveyors to heavy-duty bag conveyors and pallet conveyors.
- Easy to Integrate: Can be easily integrated into your existing systems like bagging machines, case sealing machines, weighing machines, and so forth.
- Effective Monitoring: Fitted with sensors that constantly monitor the machine status to prevent any failure.
- Effective After-Sales Support: Tough design allows uninterrupted manufacturing process operation around the clock.
Conclusion
Material handling conveyor systems may aid FMCG manufacturing facilities in reducing manual labor, improving product flow and decreasing the possibility of packaging damage. It should be properly set up based on the sizes, weight and speed of your packages and facilities. Make a list of the products you handle and determine how your conveyor system integrates with your case packer and case sealer machines.
FAQs
1. What is the main function of a material handling conveyor in FMCG packaging?
It handles many functions, such as:
- Moves products between packaging stages.
- Connects filling, weighing, packing, and storage areas.
- Minimizes manual labor.
- Avoids product damage.
- Ensures continuous operation of the line.
2. How are the belt and roller conveyors different?
Belt conveyor: Products are moved through a belt. It is more suitable for moving small items and those that come in pouches.
Roller conveyor: Products are transported using the rolling effect of the rollers. It is best suited for transporting packed items.
3. How is zero-pressure accumulation helpful in protecting FMCG products?
Zero-pressure accumulation ensures that there is no contact between items on the conveyor. The sensors control each zone and slow down the process when required to prevent boxes from colliding with each other.
4. How does a conveyor connect with a case packer, case sealer and inspection station?
It feeds packs or cases at a steady pace and spacing. Heights, transfer points and control signals need to match each machine, so confirm them early with every supplier.
5. Can one conveyor line handle several SKUs and pack formats?
Often yes, with adjustable guides, variable speed settings and quick changeover features. Share your full range of formats with the supplier so they can confirm it.
Ready to Optimize Your Packaging Line Throughput?
Don’t let your production conveyor system slow down with unnecessary stops. Share your pack types, case sizes and line speeds, and the team can suggest conveyor options for your plant.
Talk To Our Engineers about your specifications and select a proper conveyor configuration.
