Idle Roller Conveyors: Flexible Solutions for Industrial Handling
Idle roller conveyors are an essential component in industrial handling and arguably represent the most economical and functional solution for transporting small to medium loads in internal logistics.
These conveyors are ideal for moving parcels, boxes, and products of varying weights along a horizontal plane. The conveyor consists of a series of cylindrical rollers positioned one after the other, sometimes with a slight incline designed to facilitate load movement.
Another characteristic of idle roller conveyors is the complete absence of electrical or mechanical transmission: unlike powered roller conveyors, conveyors with idle rollers utilize gravity and lack of friction to move loads, without the need for a motor, as is the case with powered roller conveyors.
Idle roller conveyors also boast excellent configuration flexibility, stemming from the simplicity of this conveyor type’s usage: it is thus possible to adapt idle roller conveyors to multiple operational contexts.
Operation of Idle Roller Conveyors
In an idle roller conveyor, low friction, roller distribution, and incline allow goods to advance along the conveyor without any pulling force.
As mentioned, idle roller conveyors consist of a succession of cylindrical rollers positioned flat or with a slight incline (usually from 3% to 5%), which are activated with a simple push or even without any intervention from the operator.
The movement of the loads is therefore ensured by gravity, generated by the inclined positioning, and by the low friction of the rollers, allowing loads to slide smoothly and naturally.
The operation of idle roller conveyors is diametrically opposed to powered roller conveyors, not only due to the absence of a motor that imparts movement to the conveyor. In powered roller conveyors, adhesion between the loads and the transport rollers is crucial to move the goods safely.
Idle roller conveyors operate exactly in the opposite way: the lower the friction between the loads and the transport rollers, the better the smoothness of movement and therefore the handling of goods along the path.
This necessarily implies the use of idle roller conveyors only for the low and medium-speed handling of small to medium-sized loads, and above all, not too heavy.
Depending on the application needs and the type of loads to be handled, the rollers of the idle roller conveyor can be made of plastic, galvanized steel, or stainless steel:
- Plastic rollers ensure excellent smoothness. Additionally, they allow the handling of loads with minimal incline, provided they are lightweight. Among the operational advantages, it is worth noting the absence of rust formation, reduced maintenance, and above all, the assurance of merchandise integrity during handling (plastic material cannot cause unintended scratches on the loads);
- Steel transport rollers, whether stainless or galvanized (to be chosen according to the application environment), offer a more robust structure, ideal for handling heavier loads. They require little maintenance and, thanks to their special treatment, are resistant to wear even in complex application environments.
Regardless of the chosen material, for an idle roller conveyor to function properly and always ensure smooth movement, it must be placed on a regular support surface.
Idle roller conveyors must not only transport products and loads along the predefined path but also provide adequate support to the products during handling, thus withstanding the weight and various conditions of shape and size of the loads.
Hence the need to design the idle roller conveyor according to the specific needs of each production environment.
Practical Applications of Idle Roller Conveyors
Idle conveyors can be used in many different ways and in various industrial sectors.
For example, curved and straight roller conveyors can be used to complete a packaging line, or extendable conveyors, where the rollers are mounted on pantographs to extend and modify the support surface, are particularly useful in handling loads that vary in size, weight, and shape.
The practical applications of roller conveyors can be diverse. Here are the main ones:
Assembly stations: rollers are very useful for improving the efficiency of the line during product assembly phases;
End-of-line systems, packaging, and packaging: roller conveyors can be used to transport the finished product in the final packaging and closing stages in boxes and containers, which will then be handled, stacked, and stored in the warehouse or shipped;
Warehouses: idle roller conveyors can be used to complete handling lines designed to connect different areas of the warehouse, transporting loads from one place to another through a simple plug & play system;
Loading and unloading docks: idle roller conveyors optimize the flow of goods and the handling of loads from the warehouse to trucks and containers and vice versa, ensuring speed, convenience, and safety.
Outside of industrial handling applications, idle roller conveyors are frequently found in airport security checkpoints and supermarkets.
Operational Benefits of Idle Roller Conveyors
Whether it’s at the end of the line, in the warehouse, or at loading and unloading docks, idle roller conveyors bring numerous operational benefits.
First and foremost, the fact that idle roller conveyors exploit reduced friction and gravity to move loads minimizes physical efforts for operators, who can rely on a completely autonomous transportation and handling system or one that requires, at most, a push to start. This also improves efficiency by allowing workers to focus on other more strategic activities.
Another advantage is the reduction of loading and unloading times: using idle roller conveyors, as well as all other automated transportation systems such as powered rollers and shuttles, allows merchandise to be handled more quickly, optimizing work timings.
In general, all systems for handling goods accelerate productivity and require fewer resources compared to other manual logistics equipment, thus proving to be a economically very convenient choice.
When we add zero maintenance for idle roller conveyors to the equation, the utility of these applications becomes evident.
Among the operational benefits, we must also mention the incredible flexibility of this roller conveyor system. Powered roller conveyors represent a modular solution that can be adapted to the needs of any industrial environment.
All this, combined with easy installation, makes them a perfect solution for the diverse needs of merchandise handling.
Custom Solutions for Your Business
The great versatility of idle roller conveyors allows for the design of solutions for virtually any scenario.
Pieri, an expert in end-of-line systems, is able to assist companies in designing and implementing complete handling systems with idle roller conveyors or other cutting-edge transportation solutions.
Through a wide and targeted range of solutions, it is possible to configure the machine-device composition and handling systems that best meet the specific needs of the work environment, whether it is a warehouse, an end-of-line application, or a loading and unloading dock.
Not just smooth and continuous movement: Pieri’s goal is to provide a solution that has the highest degree of adaptability to the evolving processes of the company it will be part of.
Pieri’s idle roller conveyors also guarantee a fast and safe system.
This is thanks to the sensors and safety components integrated into the merchandise transportation solutions, which help reduce the risk of damage to boxes and loads and, above all, facilitate the work of operators, who know they can rely on an automatic system that does not require special supervision.
Convenience, versatility, and safety are the key values that machinery must have to meet the needs of modern industrial systems, especially in a competitive and ever-evolving market.