A pallet conveyor is a powered material handling system that moves loaded or empty pallets between work areas using rollers, chains, belts, or transfers.

Unlike package conveyor, pallet handling conveyors are engineered for heavy loads typically running from 1,000 to 6,000 pounds, with reinforced frames and drive systems designed around 40 by 48 inch pallets, slip sheets, drums, and bulk containers.

They're used for receiving, palletizing and depalletizing, AS/RS infeed and outfeed, outbound staging, and end-of-line operations like stretch wrapping and labeling.

Most pallet conveyor systems combine several conveyor types based on load and layout. Chain-driven live roller (CDLR) handles general heavy loads in dirty environments.

Drag chain conveyors carry pallets with formed feet, irregular bottoms, or extreme heat up to 6,000 pounds. Plastic belt and mat-top conveyors support unstable or footed loads that rollers can't handle. Zero pressure accumulation lines stage pallets without back pressure.

Turntables and right-angle transfers change direction without changing orientation. Vertical reciprocating conveyors and pallet lifts move pallets between mezzanines and floors.

Standard pallet conveyors handle loads from 1,000 to 4,000 pounds per pallet, which covers the typical 40 by 48 inch loaded pallet.

Heavy duty pallet conveyor systems (drag chain or reinforced chain) handle up to 6,000 pounds, and engineered systems can move 10,000-pound loads when the application calls for it.

The right capacity depends on your pallet design, product weight, accumulation needs, and whether the conveyor is transporting or stopping the load.

Gravity pallet conveyor uses unpowered rollers set at a slight pitch to move pallets by inclination. It's lower cost, lower maintenance, and ideal for short staging runs and dock loading.

Powered pallet conveyor (chain-driven, motor-driven roller, or chain) gives controlled speed, accumulation, and integration with palletizers, robots, and AS/RS.

If your facility needs predictable throughput, sequencing, or hand-off to automation, powered is the answer. If you're staging pallets for dock loading or buffering at floor level, gravity is often enough.

Accumulation lets pallets queue on the conveyor without crashing into each other or building up back pressure.

An accumulating pallet conveyor uses zoned drives, zero pressure logic, and sensors so each pallet stops independently.

This matters when you're staging pallets for a stretch wrapper, palletizer, or shipping lane and need clean separation. Indexing pallet conveyors take this further, advancing one pallet at a time to a fixed position for assembly or inspection.

Start with your load. Pallet design (block, stringer, footed, plastic thermoform, steel rack), weight, and condition determine which conveyor type will actually work. Then map throughput targets, accumulation needs, and integration points: palletizers, robots, AS/RS, stretch wrappers, dock doors.

Decide whether you're buying equipment or a system. A handful of CDLR sections is equipment. A receiving-to-shipping flow with transfers, lifts, and controls integrated to your WMS is a system.

The wrong call here is the single biggest source of regret on pallet conveyor projects. The fastest way to get this right is a site walk with an engineer who designs, installs, and services the system.