Unpacking Belt Conveyors – The Backbone of Modern Packing Conveyor Systems

Oct 19, 2023 | Belt | 0 comments

When shipping and handling pose significant challenges, packaging systems stand out as the key solution, enabling the rapid and efficient transportation and preparation of vast product volumes.

At Power Pack Conveyor Company, we pride ourselves on specializing in the design and construction of these critical systems, serving integrators and end-users across various industries.

Central to these systems are packaging conveyors engineered to move, sort, and categorize products. With various types of packaging conveyors available, each is designed for specific tasks, ensuring exceptional performance and a seamless fit into any workflow.

The Ubiquity and Advantages of Belt Conveyors

At its core, a belt conveyor comprises a continuous loop of material—the conveyor belt—that rotates around two or more pulleys.

  • Versatility in Handling: One of the primary draws of belt conveyors is their adaptability. Whether you’re moving granules, boxed items, or even fragile glassware, there’s a belt conveyor tailored for the task.
  • Efficiency in Continuous Operations: In the fast-paced world of packaging, downtime is a luxury few can afford. Belt conveyors, known for their reliability, ensure operations run smoothly, keeping the packaging line active and efficient.
  • Safety First: For delicate or prone-to-damage products, belt conveyors offer a gentle touch, ensuring products reach their destination unscathed.
  • Cost-Effective Solutions: Belt conveyors are notably low maintenance. This durability, coupled with their energy efficiency, ensures they remain a cost-effective choice for packaging lines.

Belt-Driven Live Roller Conveyors

The Belt-Driven Live Roller Conveyor (BDLR) is a unique hybrid combining belt and roller conveyors’ features. It uses belts to drive rollers, moving products along the line. This dual mechanism provides smooth operation and adaptability, making it suitable for diverse packaging applications.

In packaging settings, BDLRs excel in moving boxed items, especially when products need to remain stationary, such as during labeling or scanning. Their design ensures products maintain a consistent orientation, a beneficial feature for barcoded or labeled goods.


  • Reduced Product Damage: The combination of rollers and belts ensures that items are handled carefully, minimizing potential damage during transit.
  • Adaptability: Given their design, BDLRs can easily handle products of varying sizes. Whether a small carton or a larger box, these conveyors adjust seamlessly.
  • Consistent Product Orientation: With BDLRs, there’s minimal risk of products twisting or turning, ensuring they remain in the desired position throughout the packaging process.


Horizontal Belt Conveyor

A Horizontal Belt Conveyor is a flat system that operates on a level plane, allowing items to be easily conveyed from one point to another without requiring specialized equipment or inclines.

Horizontal Belt Conveyors are frequently used in primary packaging processes, where items transition from production lines to initial packaging phases. Their simple design makes them ideal for transporting individual products, bagged items, or even small boxes.


  • Simple and Efficient Design: The straightforward mechanism ensures easy maintenance and fewer operational hurdles.
  • Scalability: Depending on the production needs, horizontal belt conveyors can be easily extended or shortened, offering scalability for businesses of all sizes.
  • Easy Integration: Their linear design facilitates smooth integration with other packaging machinery, labeling systems, filling machines, or sealing apparatuses.

Floor-To-Floor Conveyor

As the name suggests, floor-to-floor conveyors are specifically designed to move materials between different floor levels. They are equipped with inclines or declines to cater to the elevation requirements and can be fitted with various belt materials suitable for the application’s specific demands.

These conveyors are indispensable in multi-level packaging facilities where products must be transported upstairs or downstairs. They’re commonly employed in large distribution centers or factories where the packaging line is spread across multiple floors.


  • Space Utilization: Utilizing vertical space becomes vital in facilities with limited ground space. Floor-to-Floor Conveyors offer the perfect solution to capitalize on this vertical real estate.
  • Seamless Vertical Transition: Unlike traditional systems requiring manual intervention for vertical transportation, these conveyors ensure a smooth transition, thus boosting efficiency.
  • Versatile Design Options: Depending on the specific requirements—whether it’s a steep incline or a gentle slope—these conveyors can be custom-designed to fit the bill.


Which One is Right for Your Packaging Need?

Choosing between these conveyor types might seem intimidating, but understanding your specific needs and the unique offerings of each system can guide you toward the right decision.

  • Scale of Operation: While Horizontal Belt Conveyors are perfect for straightforward, linear operations, the BDLR shines in scenarios demanding adaptability. For multi-level operations, Floor-to-Floor Conveyors are the go-to choice.
  • Product Handling: Consider the nature of the products you’re dealing with. For items that require consistent orientation, BDLRs might be more fitting. For basic conveyance, a Horizontal Belt Conveyor would suffice. If elevation is a key concern, then the Floor-to-Floor Conveyor becomes a prime contender.
  • Integration with Existing Systems: Consider the machinery and systems you already have. While Horizontal Belt Conveyors and BDLRs can integrate seamlessly with primary packaging systems, a Floor-to-Floor Conveyor might be essential for multi-tiered packaging operations.


Cost Implications: Investing in the Right Conveyor

The upfront cost of a conveyor system varies based on its type, length, material, and customization. While Horizontal Belt Conveyors might be less expensive initially, specialized systems like the BDLR or Floor-to-Floor conveyors might have higher initial costs due to their specific functionalities.

The return on investment isn’t just about the initial price. Efficiency reduced labor costs, and minimized downtime are pivotal in calculating the ROI. A well-integrated conveyor system can lead to significant savings in the long run, offsetting the initial expenditure.

Tailoring a conveyor to meet specific needs can add to the costs but can be a worthwhile investment, considering the increased efficiency and adaptability to unique packaging requirements.


Choosing the Perfect Conveyor for Packaging Excellence

Packaging is a critical component of the manufacturing and distribution process. Ensuring products are packaged efficiently, safely, and in a timely manner directly impacts a company’s bottom line. In their various forms, belt conveyors have proven invaluable assets in this domain.

For businesses looking to optimize their packaging processes or systems integrators looking to recommend the most efficient solutions, understanding the nuances of each belt conveyor type is crucial.

In all cases, our engineering team considers all of your requirements during the design phase. This ensures that the chosen model operates exactly as needed for your industry, making our solutions tailored and precise.

Remember, the right conveyor system isn’t just about movement—it’s about facilitating a seamless, efficient, and productive packaging process that aligns perfectly with business objectives.


About the Author

Dan Farrar is the CEO of Power Pack Conveyor Company, a pioneering industrial conveyor manufacturer since 1929. Power Pack Conveyor Company specializes in designing, engineering, and manufacturing conveyors, conveyor components, and turn-key systems for OEMs, System Integrators, and Distributors.

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