Key Considerations for Choosing a Powered Accumulation Conveyor
Powered accumulation conveyors are essential for efficient material handling, allowing products to move safely and seamlessly through distribution centers, warehouses, and production lines. Zero-pressure accumulation conveyors ensure that products are spaced properly, preventing damage and optimizing workflow. However, selecting the right conveyor system requires careful planning. Below, we outline the key factors you should consider to maximize performance, efficiency, and reliability in your accumulation conveyor system.
Whether handling lightweight packages or heavy-duty pallets, choosing the right conveyor optimizes throughput, minimizes downtime, and improves safety.
Here are top considerations for accumulation conveyors and some leading solutions based on them:
1. Product Size Requirements
Accumulation conveyors must be designed to accommodate both small and large products while maintaining smooth flow.
✅ Minimum Product Length:
- Should be three times the tread roller spacing for package handling conveyors.
- For pallet handling conveyors, it should be four times the tread roller spacing.
✅ Maximum Product Length:
- Should be 3 inches less than the zone length for package handling conveyors.
- For pallet handling conveyors, the maximum length should be 6 inches less than the zone length.
⏩ Tip: Choosing the right zone length ensures seamless accumulation and prevents bottlenecks.
2. Product Width & Shape Considerations
✅ Product should not exceed the conveyor’s Between Rail Width (BRW).
✅ Clearance checks are required if curves are part of the accumulation system.
✅ Products with overhangs, handles, or V-shapes may cause sensor interference, leading to potential accumulation issues.
⏩ Tip: A firm, flat bottom is required for consistent movement. Pallet-type products should have a conveyable surface with runners in the direction of travel.
3. Product Flow & Conveyor Direction
✅ Most zero-pressure accumulation conveyors are designed for one-direction flow.
✅ If a reversing operation is needed, consult the manufacturer to ensure compatibility.
⏩ Tip: Proper product orientation prevents jams and improves efficiency, especially when integrating automated systems like sortation or scanning.
4. Conveyor Speed & Zone Control
✅ Standard speeds are specified for each conveyor type. Adjusting speeds outside of manufacturer recommendations may affect accumulation performance.
✅ Bed lengths are supplied in multiples of zone lengths. Conveyor modifications may be required to fit unique layouts.
⏩ Tip: Adjusting conveyor speed too high or too low can cause spacing issues and affect downstream operations.
5. Hytrol Product Solutions by Weight & Load Capacity
Different accumulation conveyors support varying weight capacities. Choosing the right one ensures proper functionality without exceeding the conveyor’s limits.
✅ Light to Medium Loads:
- 138-NSPEZ – Supports up to 10 lbs. per driven roller
- 190-NSPEZ – Handles up to 15 lbs. per driven roller
- 190-E24EZ – Maximum of 50 lbs. per zone
✅ Heavy-Duty Loads:
- 25-LREZ – 1,000 lbs. per linear foot, with a total load capacity of 4,000 lbs.
- 199-CREZD – 1,250 lbs. at 35 FPM
- 36-CREZD – 5,000 lbs. at 26.5 FPM
- DCEZ-60, DCEZ-63 – 6,000 lbs. at 30 FPM
⏩ Tip: Always ensure that your conveyor selection aligns with your product's weight to prevent system overload and reduce maintenance costs.
If you're looking for the best accumulation conveyor solution, consult with our experts to find the right system for your specific needs.