Advantages of Using Roller Conveyor Systems in Material Handling

Injury risk and energy waste are two big, fixable costs in secondary packaging. 

In 2023, U.S. private industry reported 2.6 million nonfatal workplace injury and illness cases, according to the Bureau of Labor Statistics. 

Within the warehousing and storage sector, overexertion seems to be the leading cause of recordable injuries, making up nearly half of all cases, most often linked to manual lifting, repetitive handling, and unnecessary travel on the floor.

Meanwhile, modern motor-driven roller (MDR) conveyors with zone control can cut conveyor energy use by 50 – 75% versus continuously running drives. 

Put simply: a well‑designed Roller Conveyor System moves the load, not your people, and it only runs when it needs to.

Why Choose a Roller Conveyor System for Secondary Packaging?

Roller conveyors are made for the space between end‑of‑line stations, checkweighers, case sealers, print‑and‑apply, palletizers, and stretch wrappers. 

A Roller Conveyor System gives you:

• Predictable flow without extra handling: Product travels at a governed pace, so downstream equipment sees a steady infeed.
• Modular growth: Add a spur, extend a run, or re‑route a corner without re‑engineering the entire line.
• Low life‑cycle cost: Fewer wear parts than comparable belt systems; with MDR, zones idle when empty, cutting power and noise.

How Roller Conveyors Reduce Risk and Improve Throughput?

• Zero‑pressure accumulation (ZPA): Each zone senses a load and only releases it when the next zone is clear. Cartons don’t bump, labels stay readable, and fragile corners keep their shape. ZPA also lets you decouple upstream and downstream machines, so a short stop doesn’t ripple through the plant.
• Ergonomics by design: Instead of pushing pallets or carrying cases, operators supervise, replenish consumables, and handle exceptions. Moving the motion to rollers directly tackles the overexertion events that swell DART or DAFW numbers.
• Fewer micro‑stops: Consistent speed and alignment cut sensor faults and mispicks at tape heads, weighers, and palletizers, improving overall OEE.

What to Specify in a Material Handling Roller Conveyor?

• Roller diameter and pitch: Match roller size (often 50–60 mm for cases; larger for heavy bags) and pitch so that at least three rollers support every item at all times. That prevents sag and keeps photo‑eyes honest.
• Drive method:
  • Gravity roller for short, simple declines or manual picking.
  • Line‑shaft for light, continuous loads where simple is best.
  • MDR (24 V DC) with ZPA for energy savings, low noise, and fine zone control near printers, weighers, and palletizers. In secondary packaging, MDR is the current best practice around inspection and end‑of‑line.
• Controls that follow takt: Zone controllers report to the PLC; recipes on the HMI set speed, gap, and release logic to match downstream takt time.
• Guarding and safety: Side guards, under‑roller pinch‑point protection, and safe access at transfers keep audits simple without slowing recoveries.

The Alligator Approach to the Roller Conveyor System

Alligator Automations’ Roller Conveyor System is designed for one purpose: keeping your secondary packaging line running smoothly, without the peaks and dips that cost you time and money.

• MDR ZPA as standard: Every key section, from inspection, print‑and‑apply, to palletizing, gets motor‑driven roller zones with zero‑pressure accumulation. This means quiet operation, energy savings, and zero product collisions.
• Recipe‑ready controls: Our PLC/HMI interface lets you pre‑set speeds, gaps, and release logic by SKU. Changeovers are quick, accurate, and fully repeatable.
• Heavy‑duty modular frames: Made from powder‑coated steel with quick‑swap rollers and plug‑and‑play motor modules, so you can replace components in minutes without tools.
• Load capacity and flexibility: Rated for up to 100 kg per meter and configurable for bagged goods, cartons, and totes, with roller diameters sized to your products.
• Tight‑radius curves and compact supports: Engineered for brownfield layouts where every square foot counts.
• Seamless integration: Turnkey connections to case packers, checkweighers, labelers, and palletizers ensure your conveyor isn’t just a link; it’s part of one coordinated system.

Conclusion

A well‑built roller conveyor doesn’t just move product; it smooths out the entire end‑of‑line flow. By cutting overhandling and idle time while reducing energy draw and noise, Alligator’s system delivers steadier loading, cleaner transfers, and a calmer dispatch area.

Facing line stoppages or uneven product flow? Let’s run a line‑balance check, size your accumulation zones, and design a roller conveyor system that works in lockstep with your palletizer. 

One supplier. One accountable, complete packing and bagging line by Alligator Automations!

FAQs

1) What are the main advantages of using roller conveyors in material handling?

Steady, zero‑pressure flow with fewer touches, lower energy use (with MDR), quieter operation, and modular growth that fits brownfield plants.

2) Are roller conveyors suitable for all types of materials?

They work best with cartons, totes, cases, and bagged goods that have flat, reasonably rigid bottoms. Irregular or very soft items may need trays or a different conveyance method.

3) How do roller conveyors improve safety in material handling?

They shift motion from people to controlled zones and add engineered guarding at pinch points, cutting the overexertion risks that drive many recordable injuries.

4) What types of roller conveyor systems are available?

Gravity, line‑shaft, and MDR (24 V DC) zero‑pressure accumulation. MDR is preferred around inspection, labeling, and palletizing for energy savings and fine control.