Choosing the right internal transport system for your warehouse

Types of conveyor belt systems

Conveyor systems are one of the most widely used internal transport systems in warehouses. There are several types, each suited for different tasks.

Conveyor belts

Conveyor belts are perhaps the most traditional and versatile of the systems, used for transporting goods over long distances in a straight line. Ideal for both light and heavy-duty tasks, they are common in environments that require continuous movement of items such as packages or bulk goods. They come in various materials, offering flexibility depending on the type of goods being transported. 

Roller conveyors

Roller conveyors use a series of rollers to move goods across the floor, typically in a gravity-fed setup. These systems are cost-effective and easy to install. They are particularly useful for warehouses that handle bulk items, especially in environments where items are loaded and unloaded manually. While they are low-maintenance, their performance can be impacted by weight fluctuations and irregular-shaped goods. 

Screw conveyors

Screw conveyors are designed for moving bulk materials that are either powdery or granular, such as grain, sand, or chemicals. This system’s screw auger moves materials through a rotating tube or trough, offering reliable transport even with challenging materials. However, it may not be suitable for fragile or bulky items. 

Spiral conveyors

For warehouses with limited space, spiral conveyors are a perfect choice. These conveyors can carry materials vertically, saving floor space while offering a continuous flow of goods. This makes them ideal for applications where vertical movement is essential, such as in multi-level storage or sorting areas.

Overhead conveyors

Overhead conveyors are suspended systems that transport materials above the floor. They are commonly used in environments where floor space is at a premium, as they free up the ground for other operations. These conveyors are highly customizable, allowing for complex layouts and designs, such as loops and curves. They are particularly useful for hanging items, such as garments or automotive parts.

While conveyors are a key part of internal transport systems, there are other options available depending on your warehouse’s needs. 

Pallet trucks and forklifts

Pallet trucks and forklifts are essential for manual material handling in warehouses. These versatile vehicles allow operators to transport goods across the warehouse floor efficiently. Pallet trucks are ideal for moving lighter loads, while forklifts handle heavier items and can reach higher storage levels. Both are flexible solutions that provide control over short-distance transport in a variety of warehouse settings.

Automated Guided Vehicles (AGVs)

Automated Guided Vehicles are mobile robots that can autonomously move materials around a warehouse. These are an excellent option for facilities that require a flexible transport system that can easily adapt to different layouts and needs. AGVs are perfect for larger facilities or those with complex needs, such as those requiring frequent changes in material flow.

Vertical Lift Modules (VLMs)

For operations that deal with small parts or high-density storage, Vehicle Lift Modules are an effective solution. VLMs provide automated retrieval of stored materials in vertical racks, which saves space and time in picking and storage.

Stacker cranes

Stacker cranes are automated systems that excel in high-density storage environments. These cranes move both horizontally and vertically within shelving systems, making them ideal for managing large, palletized loads. Often used in high-bay warehouses, stacker cranes improve storage capacity, increase retrieval speed, and reduce the need for manual handling, enhancing overall warehouse efficiency.

Robotic palletizing systems

Robotic systems that can automatically palletize and depalletize materials are ideal for highly automated warehouses that need to reduce manual labour in packaging areas. They improve consistency, speed, and safety.

• Warehouse size & layout: Larger warehouses may benefit from overhead or spiral conveyors, while smaller operations might find roller conveyors, pallet trucks, forklifts, or AGVs more suitable. Stacker cranes are also ideal for high-bay storage systems where space efficiency is crucial.
• Type of goods: Consider whether your materials are light, bulky, or require special handling. This will dictate whether a conveyor system or something more specialized (like screw conveyors, VLMs, or stacker cranes) is needed.
• Flexibility & scalability: Some systems, like modular conveyor belt systems, pallet trucks, and forklifts, offer more flexibility and can grow with your business. Be sure to choose a system that can adapt to future needs.
• Cost efficiency: While the upfront cost of systems like spiral and overhead conveyors may be high, they can offer long-term savings through improved space utilization and labour efficiency. Pallet trucks and forklifts, on the other hand, are cost-effective solutions for short-distance transport.