Start With Your Production Process, Not the Conveyors

Choosing the right conveyor system is a critical decision for any manufacturing company. The wrong choice can lead to production bottlenecks, frequent downtime, rising maintenance costs, and even safety risks. On the other hand, a well-designed conveyor system can significantly improve efficiency, product quality, and long-term return on investment.

However, many buyers discover too late that selecting a conveyor system is far more complex than simply choosing a belt, roller, or chain conveyor from a catalog.

This guide is written to help you understand how to evaluate your production needs, avoid common selection mistakes, and find a conveyor system that truly fits your process—not just today, but in the future.

1. Start With Your Production Process, Not the Conveyor

One of the most common mistakes buyers make is starting with the conveyor type instead of the production process.

Before talking to any supplier, ask yourself these key questions:

• What product am I conveying?

• What happens to the product before and after conveying?

• Is the conveyor part of a single machine or a full production line?

• Does the product move continuously or in batches?

For example:

• A food packaging line has very different requirements than an automotive assembly line.

• A fragile product requires gentle handling, while a heavy industrial component needs robust support.

• A manual-assisted line requires different speeds and ergonomics than a fully automated line.

The correct conveyor system is always process-driven, not product-driven alone.

2. Clearly Define the Product Characteristics

Product details directly affect conveyor design. Do not underestimate this step.

You should clearly define:

Product size and weight

• Length, width, height

• Single-item weight and total load per meter

Product condition

• Hot, cold, oily, dusty, wet, or sticky

• Sharp edges or smooth surfaces

• Stable or easy to tip over

Product orientation

• Can it rotate?

• Must it remain upright?

• Does it need positioning or indexing?

A conveyor that works perfectly for cartons may completely fail for soft bags, glass bottles, or irregular metal parts.

This is a High Level Stacker we design for packaging flour bags.

3. Understand Your Production Capacity and Speed Requirements

Many buyers focus only on current output, but experienced manufacturers think one step ahead.

Ask yourself:

• What is my current production rate?

• Will production scale up in 1–3 years?

• Does the conveyor need to handle peak loads or just average output?

Key considerations:

• Conveyor speed must match upstream and downstream equipment

• Buffer zones may be required to prevent line stoppages

• Overdesigning slightly is often smarter than running at maximum capacity 24/7

A conveyor system should support production growth, not limit it.

4. Choose the Right Conveyor Type for Your Application

There is no “best” conveyor system—only the most suitable one.

Below are common conveyor types and where they are typically used:

Belt Conveyors

This is a belt conveyor we deisgn for Logistics package.Its for lightweight products.

Best for:

• Lightweight to medium-weight products

• Continuous movement

• Food, packaging, electronics, and general manufacturing

Limitations:

• Not ideal for sharp or extremely hot products

• Belt wear requires regular inspection

Roller Conveyors (Gravity or Powered)

Best for:

• Cartons, pallets, totes

• Accumulation and sorting

• Warehousing and logistics lines

Limitations:

• Not suitable for soft or unstable products

• Requires flat-bottom products

This is a Roller Conveyor System. Its load-bearing capacity is much higher than that of the belt line.

Chain Conveyors

Best for:

• Heavy loads

• Pallets, metal parts, automotive components

Limitations:

• Higher noise and maintenance

• Less flexible for layout changes

Modular & Flexible Conveyors

This is a double-speed chain conveyor system,also named accumulation conveyor system .It is more intelligent than other conveyor systems.

Best for:

• Frequently changing layouts

• Multi-product lines

• Short-term or seasonal production

Limitations:

• Lower load capacity

• Higher cost per meter in some cases

A professional conveyor manufacturer should help you match conveyor type to application, not push a standard solution.

Conveyor Price Comparison Table

Note: Prices below represent relative cost levels commonly used in industrial automation projects. Actual prices depend on conveyor length, load, speed, customization, and control requirements.

5. Consider the Layout and Space Constraints Early

Space is often the biggest hidden constraint in conveyor projects.

From a buyer’s perspective, you must evaluate:

• Available floor space

• Ceiling height

• Columns, walls, and existing machines

• Operator walkways and safety zones

Key layout questions:

• Straight or curved conveyors?

• Single level or multi-level?

• Is vertical transfer required (lifts, elevators)?

A well-designed conveyor system maximizes throughput without wasting valuable factory space.

6. Automation Level: Manual, Semi-Automatic, or Fully Automatic?

Not every production line needs full automation. Over-automation can be just as problematic as under-automation.

Ask:

• Are operators currently required for loading/unloading?

• Is labor availability a long-term concern?

• Does automation improve consistency or just add cost?

Common scenarios:

• Manual conveyors for low-volume or flexible production

• Semi-automatic lines with sensors and controlled stops

• Fully automated systems integrated with robots, AGVs, or AS/RS

The correct conveyor system should align with your automation strategy, not force one.

Compared to full automation, a combination of manual operation and semi-automatic processes might be the most suitable configuration for many production lines.

7. Integration With Existing Equipment

Many buyers are upgrading or expanding existing production lines rather than building from scratch.

Important integration points:

• PLC and control systems

• Sensors, scanners, and vision systems

• Packaging machines, robots, or test stations

A major selection risk is choosing a conveyor that:

• Cannot communicate with existing controls

• Uses incompatible standards

• Requires extensive rework later

From a buyer’s view, system compatibility is just as important as mechanical design.

8. Reliability, Maintenance, and Total Cost of Ownership

Price is important—but it should never be the only factor.

Smart buyers evaluate:

• Component quality (motors, bearings, belts)

• Ease of maintenance

• Spare parts availability

• Expected service life

A cheaper conveyor system may:

• Break down more often

• Require frequent belt or roller replacement

• Increase long-term operating costs

Always ask suppliers about:

• Maintenance intervals

• Common failure points

• After-sales support

Total cost of ownership matters more than initial price.

9. Safety and Compliance Requirements

Safety is not optional—and it directly affects system design.

Key safety considerations:

• Emergency stop systems

• Guards and covers

• Anti-pinch and anti-fall designs

• Ergonomic working heights

Depending on your market, compliance may include:

• CE

• UL

• OSHA

• Food-grade standards (FDA, EHEDG)

A reliable conveyor supplier designs safety into the system, not as an afterthought.

Safty Guarding System are being increasingly widely applied.

10. Choose the Right Conveyor System Supplier

The supplier is just as important as the equipment itself.

Look for a manufacturer who:

• Asks detailed questions about your process

• Offers customized solutions, not only standard models

• Has experience in your industry

• Provides engineering support, not just sales quotes

Red flags:

• One-size-fits-all proposals

• Unclear technical details

• No discussion of future scalability

A good conveyor system is the result of engineering collaboration, not a simple purchase.

Jinan Join industrial might be the enterprise you are looking for.Our company is a factory with 13 years of experience in manufacturing non-standard automated equipment. In addition to the conveying system, we also offer Automated Assembly Equipment that can be integrated with the conveyor system. We have experienced mechanical designers and electrical designers, along with a comprehensive after-sales service and excellent support. Act as a supplier for several large enterprises.

Conclusion: The “Correct” Conveyor System Is the One That Fits Your Reality

Finding the correct conveyor system for your production is not about choosing the most popular type or the lowest price. It is about understanding your process, planning for growth, and working with a supplier who designs around your real needs.

When done right, a conveyor system becomes a long-term productivity asset—quietly supporting efficiency, quality, and profitability every day.

If you are evaluating conveyor solutions, focus on fit, flexibility, and reliability, and the right system will naturally follow.

If you still have some questions ,Contact us and we will help you analyze which conveyor system is suitable for your factory.