How to Choose Roller Conveyor for Your Industrial Production Line

A roller conveyor is an industrial conveyor system that uses a series of rotating cylinders (rollers) to move products from one point to another. Depending on your workflow, the system can be manual (gravity roller conveyor) or motor-driven (powered roller conveyor). Roller conveyors are widely used in industries such as:

• Food & Beverage
• Pharmaceutical
• Warehousing & Logistics
• Automotive
• Electronics & Light Manufacturing

With their efficient and modular design, roller conveyors improve production speed, reduce manual handling, and increase workplace safety.

Types of Roller Conveyors and Their Functions

Gravity Roller Conveyor

The gravity roller conveyor operates without a motor — products move by gravity or manual push. This type is ideal for simple transfer lines, such as packing, sorting, or inspection areas.

Best For:
• Lightweight to medium-weight products
• Manual packing and sorting areas

Advantages:
• Low investment cost
• Easy to install and relocate
• Minimal maintenance

Disadvantages:
• Not suitable for full automation
• Requires slope or manual assistance

Power Roller Conveyor

A powered roller conveyor uses a motor drive — typically via chain or belt — to move products continuously. It’s ideal for automated production systems and high-volume operations.

Best For:
• Heavy products or large volumes
• Automated production lines with sensors or PLC integration

Advantages:
• Stable and controllable speed
• High efficiency and productivity
• Compatible with automation systems

Disadvantages:
• Higher initial and maintenance cost

Flat Roller Conveyor

The flat roller conveyor provides a stable, even surface for flat-bottomed products such as boxes, trays, or packaged goods.

Best For:
• Inspection, packaging, or labeling processes

Advantages:
• Stable and safe for packaged items
• Compatible with sensors or automation integration

Disadvantages:
• Not suitable for irregular or round items

Flexible Roller Conveyor

A flexible roller conveyor can be extended, folded, or curved to adapt to different working areas. This type is ideal for warehouses, loading docks, or variable logistics routes.

Best For:
• Dynamic warehouse layouts
• Loading and unloading areas

Advantages:
• Highly flexible and easy to adjust
• No need for permanent installation

Disadvantages:
• Limited load capacity
• Less ideal for long-term continuous use

Ball Transfer Conveyor

Unlike traditional rollers, this system uses free-rotating steel balls that allow products to move in any direction (360°) without lifting. Ball transfer conveyors are perfect for transfer, sorting, and direction-change points.

Best For:
• Flat-bottom items (boxes, pallets, metal plates)
• Workstations and distribution areas

Advantages:
• Smooth multi-directional movement
• Ideal for stationary transfer zones
• Easily integrated with other conveyor systems

Disadvantages:
• Not suitable for uneven or heavy items
• Inefficient for long-distance transfers

How to Choose the Right Roller Conveyor

1. Type of Product. Is your product box-shaped, cylindrical, or irregular? Flat-bottom items work best with standard roller conveyors, while lighter items requiring flexible movement may suit ball transfer conveyors.
2. Product Weight and Size. Heavier items require larger-diameter and thicker rollers to ensure smooth and safe handling.
3. Production Environment. For wet or corrosive environments, choose stainless steel roller conveyors for durability. In dry or indoor environments, galvanized steel or aluminum options are sufficient.
4. Automation Requirements. If your production system uses sensors, interlocks, or PLCs, choose a powered roller conveyor for reliable automated operation.
5. Space Flexibility. If your workspace frequently changes layout, a flexible roller conveyor allows for easy adjustment without permanent installation.

If you’re looking for a customized, modular, and expandable roller conveyor system, the Connect Automation team can help you design and build the perfect conveyor solution tailored to your industrial needs.