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CCL have vast experience of providing conveyors and conveyor systems to the warehouse and logistics sectors. We have worked with all manner of companies ranging from small, local warehouse and logistics businesses, to some of the world's highest profile brands and corporations.
These are the Ford Transits of the conveyor world. Reasonably inexpensive, sturdy, and used EVERYWHERE. If you go into a warehouse and see a conveyor with a green belt, it will almost certainly be a 2-Ply PVC belt.
Unlike roller conveyors (see below), a belt conveyor presents a smooth, flat surface to the carried product. This allows them to take products of all shapes and sizes, including "floppy" items such as bags etc. The conveyors can cope with moderate weights of around 200Kg per meter length or so. (though we CAN produce belt conveyors that can take much more, if necessary).
PVC belt conveyors can be formed into bends and corners, though it is very expensive to do this. Plastic modular bend units (see below) are usually a superior solution.
When fitted with a contoured "grip" surfaces and flights, belt conveyors can take products up and down inclines. They are - for example - very popular for mezzanine-floor conveyors, in which packages are transported to and from a high-level storage area, or even between stories in the factory.
This is probably the second-most popular conveyor system for warehouse operations. They are simple, inexpensive, and last forever with almost zero maintenance, and can range from light loads of a few kilograms, to ultra-heavy-duty pallet conveyors carrying loads of thousands of kilograms
They DO have limitations, however. They work best with rigid packages of uniform size. They CAN carry mixed loads, but very light packages might "stall" and refuse to roll down the conveyor under gravity. Very heavy items, on the other hand, can get "runaway train" syndrome and crash into the end-stops (or onto the floor, if you don't have end-stops), potentially damaging the package. The conveyors are also not very good at transporting floppy items, as these can sag into the gaps between the rollers, and stall. (transporting Jelly is RIGHT out ! ).
Gravity roller conveyors CAN go around corners and bends, but again this is only truly successful and reliable if the packages are all (roughly) the same size and weight. You have to "tune" the conveyor bend incline to ensure that the packages negotiate it without jamming on the outside of the bend, or stalling, which may not work very well with a wide variety of package dimensions and weights.
One popular use of gravity roller conveyors in a warehouse is lorry unloading. Short lengths of conveyor - on castors - can be wheeled out to the lorry and daisy-chained together. Afterwards they can be split up and wheeled into storage. We can also provide expanding gravity conveyors that stretch out for use, but then scrunch up for storage.
Sometimes, a gravity roller system just doesn't cut the mustard. This might typically be when packages need to be moved [i] under control [/i], such as when indexing. (the packages only move when a new package is introduced at the beginning of the line, and they all stop again once the new package has traveled a little way .
There are two basic types of roller conveyor...
All of the rollers are simultaneously driven by a series of chains that link the rollers together, and to a central motor. Unless there is a sensor at the end of the conveyor to stop the motor, the packages will ultimately fall off the end. If there IS an end stop, then the packages will stop, but the rollers will continue to turn underneath them, potentially abrading the underside of the package and causing damage. To avoid this scenario, many people opt for the Lineshaft Conveyor.
These feature rubber bands that connect each roller to a long, underslung drive shaft that extends the length of the conveyor. These allow for "accumulation". The conveyors feature an end-stop, that prevents the package falling off the end. When a package reaches this end-stop and stops, the friction between the roller and the underside of the package causes the rubber bands to "slip", and the roller stops. This prevents the roller "chewing away" at the underside of the package.
This is very good for lightweight packages (a couple of dozen kilograms), but not for very heavy loads, which can cause the bands to slip from day one, and for the package to 'stall' on the conveyor before it reaches the end.
The conveyor for all seasons ! It can form complex bends, loops and elipses, go up and down inclines, it is cut resistant, and even allows airflow around the product !
Technically a form of chain, this conveyor type provides a rigid flat surface to the carried product. This allows it to carry products of all shapes and sizes, even very small or "floppy" items.
The system is highly durable, and has the advantage of modularity. The belt is composed of hundreds of little "cells", held together by joining rods. If the belt is somehow damaged, then rather than replacing the entire belt, the damaged cells can be removed, and a new 'patch' locked into place, saving a lot of money.
The conveyors ARE slightly more expensive than standard belt conveyors, but this is offset by their long life and modularity.
Mezzanine floors are a very popular solution for increasing available floorspace within a warehouse, and are typically used to store less frequently-accessed packages.
A bi-directional conveyor is a highly efficient method for moving goods and packages between the ground floor and the mezzanine level quickly, simply, and on-demand.
Featuring high-grip belts and multiple safety control sensors, CCL can provide cost-effective durable conveyor solutions for this application. Conveyors can run up the side of the mezzanine, or even penetrate directly into it with a 'trap-door' access point.
Whether you require conveyors or conveyor systems to cover 10,000 sq ft or 100,000 sq ft, no matter what the floorspace CCL can provide you with a complete bespoke system, or individual conveyors to integrate into your existing conveyance process. An array of individual conveyor types can be utilised to enhance your business model, leading to great time and cost savings. As leading engineers of bespoke conveyors we have vast experience of providing conveying solutions of all kinds, whether for use at floor level, overhead rail level, or vertical direction transition.
If you would like more information on these conveyor case studies, or any other CCL conveyors or conveyor systems, call us on 01509 974215 today for an informal, no obligation chat. We’re here to listen to your conveyor enquiry and help provide you with complete conveying solutions.