Hytrol’s Legacy of Innovation and Excellence in Conveyor Technology

In this edition ofThe Warehouse Floor podcast, Tim Hoj, CEO of Hoj Innovations, sat down with Boyce Bonham, Vice President of Engineering and Product Design at Hytrol Conveyors. 

Celebrating a partnership of nearly 60 years, the conversation explores Hytrol’s innovative technologies, customer-centered approach, and forward-thinking vision that continue to revolutionize material handling.

Table Of Contents

1. The Power of Partnership and Tradition

2. Continuous Innovation: Technology at the Forefront

3. Training: Investing in Customer Success

4. Game-Changing Technologies: EasyLogic and E24

5. Sortation: Meeting the Needs of Modern Industry

6. Future-Ready Solutions: Plug-and-Play Conveyors

7. AI and Manufacturing: Accelerating Lead Times

8. Summary

The Power of Partnership and Tradition

The partnership between Hoj Innovations and Hytrol began in 1966, just two years afterHoj’s founding as an overhead crane fabricating company. Rooted in trust and shared innovation, the collaboration has grown into a six-decade legacy of success.

“Our founders were good friends who believed in the growth of our companies through technology, staying current with the industry’s needs,” Boyce Bonham shared.

This foundation laid the groundwork for a thriving relationship that combines engineering excellence with a customer-first focus, making both companies leaders in the material handling industry.

Continuous Innovation: Technology at the Forefront

Hytrol has always embraced the challenge of innovating and adapting to meet evolving needs. 

A prime example is theHytrol Technology Center, established in 1992 as a hub for product development and customer collaboration. This facility allows for real-world product testing, ensuring that solutions are practical and effective.

With over 39 years of experience at Hytrol, Boyce Bonham has seen the company evolve to address real-world challenges. “Seeing a need in the marketplace and solving problems through product innovation has been one of the most rewarding parts of my career,” Boyce shared.

This commitment to innovation, supported by a deep understanding of the industry, ensures that Hytrol remains a leader in delivering solutions that help businesses thrive.

Training: Investing in Customer Success

Training is a cornerstone of Hytrol’s customer-centric approach. The company offers tailored learning opportunities to help both sales teams and maintenance personnel optimize their operations:

• On-Site Maintenance Training: Expert technicians provide practical instruction at customer facilities.

• Technology Demonstrations: Customers receive real-time feedback to enhance their systems.

• Sales Schools: Training for integration partners ensures they understand pricing, application knowledge, and system design.

“Training is critical. We focus heavily on equipping our integration partners and their teams with the knowledge to maintain efficiency, reduce downtime, and optimize equipment,” Boyce explained.

Hytrol’s on-site training program is particularly valuable for businesses that cannot afford to send their teams off-site. “Many companies can’t risk sending maintenance teams away from their facilities. That’s why we send training personnel directly to the customer site to deliver hands-on instruction,” Boyce added.

This approach not only enhances customer convenience but also provides Hytrol’s team with valuable feedback on product performance, enabling continuous improvement.

Game-Changing Technologies: EasyLogic and E24

Hytrol’s innovative products, such as theEasyLogic Accumulation System and theE24 product line, simplify material handling and improve operational efficiency.

EasyLogic Accumulation System Designed to replace outdated mechanical systems, EasyLogic uses electronic zone controls for efficient conveyor operation. Key features include:

• Smart Controls: Zones can be adjusted via smartphone for flexibility.

• Energy Efficiency: Idle zones power down automatically to save energy.

• Real-Time Feedback: Alerts provide timely maintenance insights.

Thousands of watt hours are saved each year by customers utilizing this new smart system.

 This is achieved by shutting down conveyor lines automatically when EasyLogic senses that products have stopped flowing - like during breaks or lunchtime. This is possible because of the sensors on the conveyor which communicate back to the PLC or Programmable Logic Controller, indicating the status of each piece of conveyor. This system is so advanced it can even detect through the use of these electronic zones which areas have mechanical problems and need attention. 

“Our new networked EasyLogic lets users configure zone behaviors on-site using a smartphone, offering unmatched adaptability,” Boyce highlighted.

E24 Product Line line leverages 24-volt technology for quieter, safer, and highly adaptable conveyor systems. Its benefits include:

• Modularity: Easily scalable for businesses of all sizes.

• Adaptability: Systems can grow alongside business needs.

• Ease of Maintenance: Simple to integrate for companies new to conveyor technology.

One of the ways in which they’ve changed the conveyor industry is with the introduction of the pancake motor - which is just one of the products in their E24 product lineup. Instead of a motor being inside a roller tube, this motor is external, which comes with the added benefit of being more flexible in nature and has quickly become one of their most sought-after pieces of machinery. 

The pancake motor is so simple and flexible that it can easily be installed in a store with a small back room if needed but is also robust enough to be integrated into massive conveyance systems moving hundreds of thousands of products yearly.

This motor is safe, quiet, and easy to maintain, making it ideal for any operation. 

Together, these systems help businesses reduce energy use, minimize downtime, and meet dynamic operational demands while being easy to use and maintain.

Sortation: Meeting the Needs of Modern Industry

Hytrol’s sortation systems address the challenges posed by rising e-commerce demands, labor shortages, and ergonomic concerns. Their solutions include:

• Small Item Handling: Efficiently sort lightweight items like poly bags.

• Large Item Conveyance: Manage heavy or oversized products such as furniture and tires.

• Space Optimization: Compact sorting zones maximize facility layouts.

“Sortation isn’t just about moving products from point A to point B; it’s about routing them to their precise final destinations, such as the proper shipping door,” Boyce noted.

There are a wide variety of products that fall under the category of “sortation.” That list includes a simple divert wheel or power pivot diverters pushing products to one location or another. It can be a more advanced sorter such as a Shoe Sorter which can sort large quantities of products every minute ranging from 5 pounds to 100 pounds easily. 

Before the rise in popularity of the e-commerce industry, individual orders were hardly ever sent down conveyor lines. Previous single orders thought to be “Non-Conveyable” are now being conveyed in poly bags down conveyor lines and sorted into differentGaylord boxes in preparation for shipping directly to the homes of customers. 

Reasons products were thought to be non-conveyable were due to size, shape, and size constraints that existed in past conveyor solutions. Examples of such products include tires or different types of furniture. Hyrtol has developed a large sliding shoe sorter that can now sort items of all shapes up to 300 lbs. 

To support businesses with older equipment, Hytrol offers modernization solutions. “For customers with older technology, we’ve retrofitted their belt-driven live rollers with 24-volt pancake motors, turning them into modern, fully accumulating systems,” Boyce explained.

These innovations improve efficiency and enhance workplace safety by automating processes traditionally handled by people. Hytorl is constantly thinking about how to handle uniquely sized products and how to improve workplace safety by reducing the need for human intervention as much as possible. 

“Finding labor can be difficult in some areas, and ergonomics make manual handling less ideal. Now, we automate the conveyance and sorting of heavier items,” Boyce added.

Future-Ready Solutions: Plug-and-Play Conveyors

Typically, conveyor will be shipped out to customers, they need to be installed and then controls setup to make sure they’re running properly. This process can take weeks or even months in some cases. 

Hytrol’splug-and-play conveyor systems make automation accessible by offering pre-assembled quick-connect solutions that are ready to use within days of delivery. Equipped with supports, casters, and start-stop stations, these systems can be rolled into place and plugged into standard outlets, reducing setup time significantly.

This innovation is particularly valuable for small and mid-sized businesses entering automation. “Customers now want a conveyor system that works like an appliance—they can roll it into place, plug it in, and start using it,” Boyce reflected.

Hytrol’s vertically integrated manufacturing model supports the success of these systems by ensuring quality control and fast lead times. “We’re a very vertically integrated manufacturing facility,” Boyce explained. “By automating our processes, we can innovate and bring products to market faster, meeting the demand for quicker solutions,” Boyce added.

AI and Manufacturing: Accelerating Lead Times

Hytrol is integratingartificial intelligence (A.I.) into its operations to improve manufacturing and order processing. AI-generated bills of materials significantly reduce lead times, enabling faster order fulfillment.

“We’re leveraging AI to create bills of materials and accelerate order flow into manufacturing, enabling us to meet lead times more efficiently,” Boyce explained.

During the COVID-19 pandemic, Hytrol’s investments in a second Arkansas facility proved crucial. “Rolling out the second manufacturing facility in Arkansas at an impressive rate allowed us to stay ahead of supply chain demand during COVID. It came at the perfect time to address challenges and provide much-needed materials,” Tim noted.

These advancements reinforce Hytrol’s ability to deliver reliable, timely solutions, even in uncertain times.

Summary

Hytrol’s legacy ofpartnership, innovation, and adaptability continues to set the standard for material handling. The company’s ability to blend forward-thinking technologies with customer-focused solutions highlights its leadership in the industry.

Looking ahead, Hytrol aims to address emerging challenges by:

• Expanding automation and AI within manufacturing.

• Enhancing workflows to improve efficiency and reduce lead times.

• Developing more accessible and scalable solutions for businesses of all sizes.

“We’re excited about the future. Our investments in AI, automation, and vertical integration ensure we’ll deliver the best products at record speed to our partners and customers,” Boyce concluded.

As businesses navigate changing market dynamics, Hytrol remains committed to providing reliable, innovative solutions that adapt to their needs today and evolve to meet tomorrow’s demands.

Discover how Hytrol’s advanced conveyor systems can revolutionize your operations with the expertise of Hoj Innovations. Our engineering teams provide tailored access to Hytrol’s automated solutions, ensuring seamless integration and optimal performance for your business. 

Contact us today to learn more!