Understanding Conveyor Systems: How They Work & Why They Matter

A conveyor system is a mechanical material handling solution designed to move goods efficiently across short or long distances in manufacturing, warehousing, and distribution environments. Conveyors typically incorporate belts, rollers, chains, or modular components and can be custom-built to suit a range of operations – from lightweight packages to heavy-duty industrial loads.

Conveyor systems play a vital role in industries by:

• Reduce Labour Costs: Automation minimises manual handling.
• Improve Workplace Safety: Less risk of injuries from lifting or moving heavy loads.
• Enhance Efficiency: Faster movement of goods boosts productivity and throughput.
• Scale with Your Business: Customisable designs meet growing operational needs.

🚫 “Only large factories need conveyor systems.” – Even small businesses benefit from automation, reducing manual labour and improving consistency.
🚫 “They’re too expensive to implement.” – Modern conveyor solutions can provide strong ROI, reducing errors and labour costs over time.
🚫 “They require excessive maintenance.” – With proper servicing, conveyor systems can last decades with minimal downtime – especially if they’re well-designed from the start.

CHS offers bespoke conveyors in a variety of formats to meet diverse material handling needs – whether you’re moving, twisting or rinsing empty cans at high speeds or transporting bulky, heavy goods in an industrial setting.

Belt conveyors are one of the most common types, ideal for transporting materials over long distances efficiently.
✔ Best for: Manufacturing, packaging, warehouses, and logistics.
✔ Advantages:

• Continuous, smooth transport for various materials.
• Cost-effective and low maintenance.
• Works with multiple belt types (rubber, PVC, stainless steel).

Ideal Applications: Long-distance transfer, controlling product flow between processes.

Roller conveyors are designed to move items smoothly using rollers, available in gravity-fed or powered options.
✔ Best for: Warehousing, e-commerce fulfilment, and sorting facilities.
✔ Advantages:

• Gravity rollers reduce energy costs.
• Powered rollers allow faster and controlled movement.
• Ideal for handling boxed or palletised products.

Specialty Options: Single-lane or multi-lane setups for streamlined operations.

Chain conveyors are built for heavy loads, offering durability and efficient transport of large materials.
✔ Best for: Automotive, steel manufacturing, and heavy industries.
✔ Advantages:

• Handles extreme loads with high reliability.
• Resistant to harsh environments (heat, debris, chemicals).
• Suitable for assembly line operations.

Modular conveyor systems consist of interlocking sections that allow for easy modification and expansion.
✔ Best for: Industries needing custom layouts (food, pharma, electronics).
✔ Advantages:

• Adaptable and reconfigurable for easy expansions.
• Individual sections can be replaced without major downtime.
• Excellent for curves, elevation changes, or constrained floor plans.

Automated conveyor systems integrate advanced technologies to improve efficiency and accuracy.
✔ Best for: Smart warehouses, high-speed logistics, and precision manufacturing.
✔ Advantages:

• Uses AI, sensors, and robotics for fully automated sorting and handling.
• Reduces labour costs and improves accuracy.
• Ideal for high-volume operations needing seamless flow.

Alongside these common conveyor types, Can Handling Systems (CHS) specialises in custom-designed solutions for niche applications:

• Single Lane Conveyor Systems
• Can Conveyor Systems (including 2 & 3 piece cans)
• Bottle Conveyor Systems
• Air Track Systems & Vacuum Conveyors
• Mass Conveyors & Rope Conveyor Systems
• Craft Brewery Solutions for cans and bottles on a tighter budget
• Conveyor depalletisers

Our specialist engineering team can produce conveyors from stainless steel or mild steel with powder-coated finishes, ensuring both durability and cleanliness – essential for food, beverage, and pharmaceutical sectors.

Selecting the right conveyor system depends on operational needs and industry-specific requirements. Key factors include:

✔ Load Capacity – Ensuring the system can handle material weight and volume.
✔ Speed & Throughput – Matching the conveyor’s speed with production demand.
✔ Durability & Environment – Selecting materials that withstand heat, chemicals, or moisture.
✔ Space Constraints – Ensuring the system fits existing floor plans or production lines.
✔ Compliance & Safety: Some industries require FDA, GMP, or specific hygienic standards.

Investing in a conveyor system should balance cost and operational efficiency. Factors influencing ROI include:

✔ Labour Cost Savings – Reducing manual handling boosts productivity and lowers expenses.
✔ Energy Efficiency – Automated and smart conveyors can reduce power consumption.
✔ Maintenance & Downtime Costs – Durable systems reduce costly interruptions.
✔ Product Damage Reduction – Smooth handling decreases waste and returns.

✔ Standard Conveyor Systems:

• Suitable for general applications with quick deployment.
• Cost-effective for businesses with straightforward material handling needs.

✔ Custom Conveyor Systems:

• Designed for unique workflow requirements (e.g., cleanroom conditions, hazardous materials).
• Enhances efficiency and adaptability with tailored features.

✔ AI-powered conveyors use automated sorting and tracking, reducing labour dependency.
✔ Smart systems with IoT sensors enable real-time monitoring and predictive maintenance.
✔ Integration with robotics and automated storage solutions improves warehouse efficiency.

🚫 Choosing the cheapest option – Low upfront costs may result in higher long-term expenses.
🚫 Ignoring future scalability – Systems should be flexible for future expansion.
🚫 Overlooking maintenance requirements – Some systems require more frequent servicing than others.

Manufacturing plants require high-speed, durable conveyor systems to maintain continuous production flow and minimise downtime.

✔ Benefits:

• Automates material handling between assembly lines.
• Reduces human error and enhances production efficiency.
• Handles diverse product sizes and weights.

Warehouses and distribution centres rely on conveyor systems to accelerate order processing and optimise storage efficiency.

✔ Benefits:

• Automates sorting, picking, and packing processes.
• Enhances inventory accuracy by reducing manual handling.
• Integrates with warehouse management systems (WMS) for efficiency.

Food processing facilities require hygienic conveyor systems that comply with strict food safety standards.

✔ Benefits:

• Made from stainless steel and FDA-approved materials.
• Reduces contamination risks with easy-to-clean modular designs.
• Supports temperature-sensitive and delicate food transportation.

Conveyor systems in the pharmaceutical industry require high precision, cleanliness, and compliance with strict regulations.

✔ Benefits:

• Designed for sterile environments with cleanroom compatibility.
• Supports accurate product transport with minimal human contact.
• Complies with GMP, FDA, and MHRA standards.

Regular maintenance keeps conveyor systems running smoothly and extends their lifespan. Key daily practices include:
✔ Lubrication – Ensuring moving parts operate efficiently and prevent wear.
✔ Belt Alignment Checks – Avoiding misalignment that can cause uneven wear or damage.
✔ Visual Inspections – Identifying loose components, debris buildup, or mechanical issues before they escalate.
✔ Cleaning Procedures – Preventing material accumulation that could disrupt system functionality.

✔ Inconsistent Movement – Irregular belt speeds or jerking movements signal mechanical issues.
✔ Unusual Noises – Grinding or squeaking sounds indicate worn-out parts.
✔ Frequent Stops or Breakdowns – Indicates a need for proactive repairs and servicing.

✔ Belt Slippage – Adjust tension or replace worn-out belts.
✔ Misaligned Rollers – Realign and tighten any loose components.
✔ Motor Failures – Check for overheating or electrical faults.
✔ Blockages & Jams – Clear debris and ensure proper belt tracking.

✔ Preventive Maintenance Programs – Scheduled servicing reduces unexpected failures.
✔ On-Demand Repairs – Quick turnaround support for critical breakdowns.
✔ Spare Parts Availability – Ensuring minimal downtime with replacement components.

✔ Predictive Maintenance with IoT Sensors – Using data analytics to prevent failures before they occur.
✔ Employee Training on Conveyor Maintenance – Ensuring operators can spot early warning signs.
✔ Establishing Maintenance Checklists – Keeping consistent maintenance routines to extend system lifespan.

CHS is a leading provider of customised, high-performance conveyor systems, offering solutions tailored to various industries.
✔ Expertise & Industry Experience – Deep knowledge in can handling, beverage, and broader manufacturing.
✔ End-to-End Solutions – From design and manufacturing to installation and servicing.
✔ Scalability & Flexibility – Systems can expand or adapt to future production changes.

CHS provides fully customised conveyor systems to optimise material handling operations.
✔ Tailored to industry-specific requirements – Whether for food processing, pharmaceuticals, or logistics.
✔ Advanced automation – Integrating AI-driven controls and smart sensors for efficiency.
✔ Modular & expandable designs – Allowing businesses to adapt to changing production needs.
✔ Stainless Steel & Mild Steel Options: Suited for food, beverage, pharmaceutical, or heavy industrial use.

✔ AI-Powered Conveyor Systems – Reducing manual handling and improving efficiency.
✔ Real-Time Monitoring & IoT Integration – Proactive maintenance strategies to minimise downtime.
✔ Sustainability-Focused Design – Energy-efficient conveyors that lower operational costs.

1. Contact CHS: Email us or use our online form to discuss requirements.
2. Site Assessment: We can visit your facility or review layouts remotely.
3. Design & Quotation: Receive a detailed proposal with transparent costs and timelines.

✔ Personalised consultation – CHS specialists assess operational needs.
✔ Site visits & feasibility studies – Ensuring optimal conveyor design.
✔ Cost & timeline estimates – Transparent pricing & delivery schedules.

✔ CHS engineers visit your facility for an on-site evaluation.
✔ 3D layout (CAD) and system design recommendations provided.
✔ Budget-friendly solutions with an emphasis on efficiency & ROI.

✔ Order confirmation & production timeline.
✔ Delivery & installation handled by CHS professionals.
✔ Ongoing support & maintenance plans to maximise uptime.

• Global Fitting Team: CHS technicians handle mechanical and electrical installations internationally.
• Customised for Your Layout: We tailor conveyors to unique floor plans and production lines.
• Ongoing Support: Maintenance packages and spare parts ensure maximum uptime.

Get in touch with CHS today for a free consultation and discover how a bespoke conveyor system can revolutionise your production process.