Conveyors are not “just transport”. A good layout turns separate machines into a stable line.
Start With the Bottleneck
Identify your slowest or most sensitive station (often labeling, coding, or inspection). Design accumulation and spacing to protect it.
Key Design Elements
- Buffer/accumulation zones before the bottleneck
- Star wheel / timing screw / gating for stable infeed
- Sensors for jam detection and automatic stop
- Side guides, rails, and change parts for container sizes
Spacing and Accumulation Rules of Thumb
- Use spacing before coders/labelers for legibility
- Add accumulation before case packing to prevent upstream stops
- Avoid long “single point of failure” conveyors without bypass options
Integration Checklist
- Line control logic (start/stop handshake)
- Electrical and safety zoning
- Changeover procedure and spare parts
- Maintenance access and cleaning plan
Inputs we need for an accurate sourcing assessment
- Product state and behavior (powder flowability, viscosity, particulates, temperature)
- Package format and size range (bag/bottle/jar; material and seal type)
- Fill range and target tolerance (e.g., 100–500 g, ±1–2 g)
- Target output (units/min or hr) and expected runtime per day
- Local utilities (voltage/phase/frequency, compressed air, clean-room/hygiene level)
- Photos or sample pack + label requirements (if any)
Common failure points (what usually goes wrong)
- Filler choice not matching product behavior (bridging, foaming, shear sensitivity)
- Poor dust control contaminating seals (powders)
- Unstable feeding causing speed fluctuations and weight drift
- Bag material/seal spec not compatible with sealing temperature or contamination
- Underestimating footprint and maintenance access space
FAT acceptance test checklist
- Run with your product or a confirmed substitute and record output stability
- Check weight accuracy vs tolerance at different speeds
- Verify sealing integrity (leak test / visual inspection) across a full shift simulation
- Confirm safety, emergency stop, guards, and basic alarms
- Capture test video and final configuration list for handover
Frequently Asked Questions
Do I always need accumulation?
If you have multiple machines, yes. Even a small buffer can reduce stop-start cycles dramatically.
What causes most jams?
Unstable infeed, container size variation, and missing guides/change parts.
Can you integrate conveyors with mixed suppliers?
Yes. We define interfaces, sensors, and control logic so different equipment works as one line.
What info should I provide?
Container dimensions, target output, station list, and available floor layout.