Conveyors and Conveying Systems Types - All You Need to Know
Every seamless production floor or warehouse operation runs behind a network of conveyors that silently do the heavy lifting. The global conveyor systems market was nearly USD 8 billion in 2021, and it will continue to grow as industries demand faster, safer, and smarter material handling.
Nevertheless, there is no universal solution. Knowing about the types of conveyors and conveying systems is the first step in developing a line that fits your operation today and will scale with you in the future.
What is Conveyor System?
A conveyor system is simply a mechanical arrangement designed to move materials (from loose powder to packaged cartons) with as little effort as possible from a person. Some are simple, like a single conveyor belt moving boxes down a line. In contrast, others are more complex, with several conveyor types working together and controlled by smart sensors and automated software.
Types of Conveyors:
1. Belt Conveyors –
When people picture a conveyor, chances are they’re thinking of a belt conveyor. These are the most widely used conveyors in the world, and for good reason. A continuous belt loop, running over pulleys, carries everything from bulk grains to finished goods.
Where does it fit?
- Bulk and unit material handling
- Light to moderate loads
- Long runs or multi-floor layouts
Did you know? The world’s longest belt conveyor stretches over 98 km in Western Sahara, moving phosphate from a mine to the coast.
2. Roller Conveyors –
Roller conveyors come in two flavors: powered and gravity-fed. Powered rollers move items with motor-driven force, while gravity rollers rely on a gentle slope or manual push. Both types excel at handling boxes, trays, and pallets in warehouses and sortation centers.
Where does it fit?
- Order picking lines
- Accumulation and buffering
- Packaging and shipping areas
3. Chain Conveyors –
Heavy, hot, or oddly shaped loads? That’s where chain conveyors step in. They use heavy-duty chains to drag or carry unit loads like pallets, barrels, or industrial parts that would destroy a standard belt or roller system.
Best suited for:
- Pallet handling lines
- Harsh or high-heat environments
- Automotive assembly
4. Screw Conveyors –
Often called auger conveyors, screw conveyors are indispensable in food, agriculture, and chemical processing. A rotating screw moves granular or powdery material through an enclosed tube. It is neat, controlled, and perfect for dusty or hazardous products.
Where does it fit?
- Moving grains, flours, or chemicals
- Inclined feeding to hoppers or mixers
- Controlled discharge rates
5. Pneumatic Conveyors –
When contamination is a concern or you need to move powders long distances — pneumatic conveyors are the answer. They use air pressure or vacuum to push or pull material through a pipeline, keeping the product enclosed and the process dust-free.
Best suited for:
- Food and pharmaceutical powders
- Cement, fly ash, or chemicals
- High-volume, enclosed transfer
6. Overhead Conveyors –
Sometimes, the most innovative use of space is above your head. Overhead conveyors are standard in automotive plants, paint shops, and garment factories. Items hang from a trolley that travels along a track, freeing up valuable floor space.
Best suited for:
- Assembly operations
- Painting and coating lines
- Hanging garments or parts
7. Integrated Conveyor Systems: Smarter by Design
Most modern facilities combine several conveyor types into a single, streamlined line. Add sensors, variable speed drives, or robotics, and you have an intelligent material flow that cuts labor and boosts uptime.
For example, Alligator Automation’s Case Conveyor System is designed to handle a wide range of box sizes without needing constant tweaks. It uses modular controls and smart sensors, so it pairs perfectly with case packers, palletizers, or stretch wrappers, giving companies a future-ready end-of-line setup without extra hassle.
How to Choose the Right Conveyor for Your Needs?
Choosing the right conveyor can be difficult, and there is no shortcut. The right conveyor will fit your product, layout, and production needs. A few questions can help steer you in the right direction.
- What type of product are you moving? Is it fragile, abrasive, sticky, bulky or consistent in shape and size?
- How much are you moving and how fast? Be sure to define the throughput required per shift or hour.
- What is your layout? Do you have tight corners, multiple levels, or limited floor space?
- Are there specific requirements by a governing body? For example, do you require food-grade material, cleanroom, or heavy-duty construction for a harsh environment?
Thinking it through at the front end eliminates some of the redesign costs and ensures your conveyor system will operate reliably from day one.
Conclusion:
Whether you’re shipping thousands of packages daily or feeding raw ingredients to a mixer, your conveyor system should make life easier, not more complicated. The right mix of belt conveyors, rollers, chains, or pneumatic lines can transform productivity and safety.
And when you add smart automation to the mix, you get more than just movement, you get traceability, real-time monitoring, and equipment that grows with your business.
Ready to upgrade or design a conveyor system that keeps up with your growth? Talk to our experts at Alligator Automation and discover a smarter way to move your products.
FAQs
What are the main types of conveyor systems?
The main types include belt, roller, chain, screw, pneumatic, and overhead conveyors. Many facilities combine them into one integrated line.What is the most commonly used conveyor type?
Belt conveyors remain the most widely used worldwide due to their simplicity and flexibility.How do I choose the right conveyor system for my application?
Look at your product type, capacity needs, plant layout, and industry standards. Working with a specialist helps you avoid costly redesigns.What industries use conveyor systems the most?
Food and beverage, packaging, automotive, mining, and e-commerce all rely heavily on conveyors and conveying systems.- How can automation be integrated into conveyor systems?
Automation can include sensors, control software, robotic arms, and IoT-enabled monitoring — all of which make your conveyor system safer, more efficient, and easier to scale.
