A roller conveyor moves cartons, boxes, and totes across a series of parallel rollers set in a steel frame. Gravity versions use a slight decline to let product roll on its own, while powered versions drive the rollers by belt, chain, or 24-volt motors. Roller conveyor suits rigid, flat-bottomed cases and carries up to 250 lbs per roller.

Key facts

•   Three types: gravity, powered (live roller), and motorized (MDR)

•   Best for rigid, flat-bottomed cartons, totes, and boxes

•   Capacity from 10 lbs per roller (light duty) to 250+ lbs (heavy duty)

•   Belt-driven live roller carries up to 200 lbs per linear foot

•   24-volt MDR runs 25 to 125 FPM, one motor per zone

•   Rollers typically 1.9 in. diameter, spaced every 3 in.

How does a roller conveyor work?

A roller conveyor carries product on rollers mounted between two side frames. The way those rollers turn defines the type. A gravity roller conveyor has no drive; the frame is pitched at a slight decline so product rolls forward under its own weight, which makes it the lowest-cost option for short transport and accumulation. A powered, or live roller, conveyor drives the rollers with a belt or chain beneath them, moving product on level runs and inclines at a controlled speed. A motorized driven roller (MDR) conveyor uses small 24-volt motors built into the frame to drive zones independently, so rollers turn only when product is present.

Roller conveyor types compared

 

Where are roller conveyors used?

•   Transport of cartons and totes between workstations

•   Receiving, pick, and shipping lines

•   Accumulation ahead of packing or sortation

•   Pharmaceutical and food handling on controlled lines

•   Curves, inclines, and declines between levels

•   Manufacturing transport of parts and components

When should you use rollers instead of a belt?

Use roller conveyor for rigid, flat-bottomed cartons and totes, where rollers move product at lower energy cost than a continuous belt. Gravity rollers add transport with no power at all. MDR drives only the zones holding product, cutting energy use and noise. Belt conveyor remains the choice for small, light, fragile, or irregular items that need continuous support. Most facilities run both, rollers for uniform cases, belt where support matters.

Plan a roller conveyor line

HOJ engineers and integrates roller conveyor as a Hytrol partner, matching gravity, live roller, or MDR to your case weight, throughput, and energy goals, then tying the line into your wider conveyor system. Talk to a conveyor specialist.