The following section is taken from our Manufacturing Automation Guide for System Integrators, a comprehensive resource on designing smarter, integrating faster, and avoiding costly surprises.
You can download the full guide here: Manufacturing Automation Guide for System Integrators.
System integrators are under more pressure than ever to deliver automation systems that are fast, efficient, and flexible. Rising labor costs, evolving safety regulations, and demand for higher throughput all contribute to the complexity of today’s integration work. In this environment, even minor oversights can result in delays, scope changes, or operational inefficiencies. One area where these issues often surface? Conveyor system design.
Conveyors are more than just a method of moving products—they’re a vital link that connects the mechanical, digital, and human elements of an integrated system. Yet because they’re often viewed as secondary to robotics or controls, they tend to be brought into planning too late. By that point, layout decisions have been finalized, control logic is mapped, and the opportunity for optimization is limited.
With those challenges in mind, this guide was created by Power Pack Conveyor Company to support systems integrators in planning and delivering more reliable conveyor integration.
With more than 90 years of experience in conveyor design, manufacturing, and integration support, we’ve worked alongside integrators across a range of industries to solve complex automation challenges.
This guide provides practical guidance on:
- Avoiding common planning and integration pitfalls
- Selecting the right conveyor system for your application
- Navigating design challenges like space constraints and product variability
- Aligning conveyor systems with robotics, AMRs, and controls
- Managing project timelines and calculating ROI
Our goal is to help you make more informed decisions—whether you’re scoping a new facility or upgrading an existing one. With the right approach, conveyors become a strategic asset that enhances the performance and reliability of the entire automation solution.
Design Decisions That Impact the Bottom Line
For many clients, automation is a major capital investment. Demonstrating ROI is essential to justifying the cost—and conveyors play a larger role in that calculation than they might appear to at first glance.
Conveyor system design affects everything from energy usage and product handling reliability to installation time and maintenance costs.
Key Factors That Influence ROI
- Installation Efficiency: Conveyors that are modular, pre-wired, or pre-assembled can significantly reduce install time and labor costs.
- Operational Uptime: Systems designed with accessible components and durable materials tend to experience fewer breakdowns and lower service costs.
- Energy Consumption: Motor sizing, drive selection, and smart controls (like zone-based actuation) all affect utility costs.
- Maintenance Requirements: Designing for preventive access, part standardization, and integration with diagnostic tools makes long-term upkeep more predictable and cost-effective.
Helping Clients Understand Value
Integrators can strengthen their proposals by articulating the cost impact of conveyor design decisions. This might include:
- A side-by-side comparison of conveyor options with lifecycle cost estimates
- Estimates for reduced labor due to automation or improved flow
- Projected energy savings from more efficient drive systems
- Downtime reduction from planned maintenance features
A well-selected and properly integrated conveyor system helps ensure not only performance, but also predictable, measurable value. By thinking beyond the initial quote and considering long-term ownership costs, integrators can deliver smarter systems that strengthen client relationships and future business.
Designing with Integration in Mind
Conveyors are more than just equipment—they’re an essential link in the larger automation system. When their design is aligned with broader project goals, the result is better performance, fewer surprises, and a smoother path from concept to commissioning.
At Power Pack Conveyor Company, we support systems integrators with the engineering expertise, insight, experience, and technical alignment needed to deliver high-performing solutions. We believe the best outcomes happen through early collaboration and shared understanding of both the opportunities and constraints.
If you’re planning your next integration project, we’re here to help ensure the conveyor system strengthens—not complicates—your design. Let’s connect early and build with confidence.
Download Manufacturing Automation Guide for System Integrators
