Powerised Roller Conveyor

The Powered Roller Conveyor is designed for continuous and efficient material movement, driven by an AC geared motor. Powered Roller Conveyor operates without zone control, utilizing a chain or belt drive mechanism for synchronized roller movement. This ensures smooth product transport across various industrial applications such as warehousing, distribution centers, manufacturing, and e-commerce logistics.

Key Advantages

Continuous Product Flow

Ensures uninterrupted material movement without zone-based stoppages.

Simple & Robust Design

Minimal control components simplify installation and maintenance.

Cost-Effective

Centralized drive reduces the number of motors required compared to ZPA systems.

High Throughput

Continuous operation enables efficient handling of large volumes.

Flexible Operation

Supports continuous running or indexing, configurable via PLC programming.

Adaptable Design

Customizable in various widths, heights, and configurations to suit industry-specific requirements.

Working Principle

Drive Mechanism

  • Roller-to-Roller (Tangential) Drive : Each roller is connected to the next using a chain or belt, forming a continuous drive loop. A centrally located AC geared motor provides the driving force.
  • Motor-Driven Rotation : The motor transmits power via a chain or belt drive, ensuring synchronized roller motion.

Operating Modes

  • Continuous Running : Rollers operate continuously, ensuring smooth product flow.
  • Indexing : Controlled start/stop operation for precise product positioning based on PLC programming.

Key Components

Conveyor Frame

Constructed from high-quality CRC steel sheet that is CNC laser cut and bent into a C-profile with collar bends, the frame features slotted flanges and defined ...

Conveyor Legs

CNC laser-cut and bent into a C-profile with slotted holes for height adjustment, the structure includes smile brackets for angle alignment and flat bottoms wit...

Powered Rollers

Available in various tube diameters — 50 mm, 60 mm, 80 mm, 90 mm, and 100 mm — and uses a Drive Mechanism based on roller-to-roller chain or belt drive.

Sensors

Photoelectric (Reflective or Through-Beam) sensors mounted at infeed and discharge points for product detection.

AC Geared Motor

Main driving force for the conveyor, controlled via VFD for speed regulation.

Control & Automation

AC Geared Motor Control

  • Powered by a centralized AC geared motor, controlled via a Variable Frequency Drive (VFD) for speed regulation.

Photo Sensors

  • Detect product presence and trigger start/stop sequences as per PLC logic.

PLC / Master Controller

  • Manages drive motor operation, start/stop sequences, and integrates with upstream/downstream equipment like scanners, sorters, and labellers.

Communication Protocols

  • Supports digital I/O and fieldbus protocols such as Ethernet, Profinet, and Modbus.
  • Speed and operational adjustments can be controlled via PLC or HMI interface.

Accessories

Safety Covers & Roller Gap Covers

Protect moving parts from exposure

Photo Sensors

For product presence detection and automated control

Cable Trays

Ensures organized wiring and easy maintenance

Stoppers & Diverters

For controlled product flow direction and separation

Singulators

Used for product sorting and alignment

Side Guides

Adjustable configurations for various product sizes

Safety & Stop Functions

Emergency Stop & Pull-Cord Switches

  • Instantly cuts power to the drive motor during emergencies, integrated into the main safety circuit.

Guards & Covers

  • Encloses rotating components to protect personnel from pinch points and meet industry safety standards.

Fail-Safe Control Systems

  • Ensures safe stoppage in case of sensor malfunctions or overload conditions.

Applications

1

Tote & Carton Handling

Ideal for warehouses and distribution centers, ensuring smooth transport of small to medium-sized packages.

2

Tyre & Automotive Part Handling

Used in assembly lines for transporting lightweight automotive components.

3

Light to Medium Pallet Transport

Handles pallets within specified weight limits, ensuring steady movement.

4

General Warehousing & Manufacturing

Enables efficient material flow in industrial production and storage environments.

5

Retail, E-Commerce & Sortation

Supports high-throughput order fulfillment systems, automated sortation, and logistics handling.

Technical Specifications

Modular powerised roller conveyor engineered for reliable, high-throughput material handling of tyres, pallets, cartons, totes, and flat-bottom items, featuring adjustable speed, PLC control, low noise operation, and robust industrial construction for automation-ready facilities.

Basic Configuration

Powerised Roller Conveyor

Conveyor Type

Modular

Conveyor Construction

50 mm, 60 mm, 80 mm, 90 mm, 100 mm

Roller Tube Dia

Steel, Zinc Plated, PU Coated

Roller Tube Material

Fixed Drive Roller

Roller Type

Sprocket, Poly Vee, Double Groove on Tube or Timing Pulley

Roller Drive Head

75, 90, 100, 120 mm

Roller Mounting Pitch

Dimensions & Accessories

1 Mtr ~ 15 Mtr

Conveyor Length

Max 3 Mtr

Conveyor Module Max Length

300 ~ 1200 mm

Conveyor Width

300 mm 2400 mm

Conveyor Height

5˚ to 10˚ Max

Inclination Angle

Safety Covers, Cable Tray ,Bottom Cover, Roller Gap Covers , Channels Side Covers, Stoppers, Pop up Etc

Conveyor Accessories

Performance & Products

30 Kg, 50 kg, 75 kg, 125 Kg / Mtr Max

Conveying Capacity

5 ~ 90 Mtr / Min

Conveyor Speed

< 70 dBa

Running Noise

(-)10°C to 40°C (humidity 10–95% non-condensing)

Ambient Temperature Range

Tyres, Wheel, Pallets, Carton Box, Plastic Bag, Tray, Totes and Mostly Flat Bottom Items.

Conveying Products

Drive & Control

AC Geared Motor, Power Roller

Conveyor Drive

By PLC

Sequence Control

By VFD or Roller Drive Card

Speed Control

HMI

Man Machine Interface

Optional

SCADA / WCS

Electrical & Communication

Profinet / Ethernet / Modbus

Communication Protocol

Profinet / Ethernet / Modbus

Real Time Communication

Photo Electric Sensors

Sensors

3 Phase (360 ~ 440 VAC)

Main Power Supply to Control Box

50 ~ 60 Hz

Rated Frequency

Structure, Accessories & Finish

Steel Wheel, Round Tube, U Channel

Side Guide

50 mm, 150 mm, 300 mm, 600 mm

Side Guide Height

High-quality CRC steel sheet

Conveyor Frame & Legs

Shot Blasted and Powder Coated

Painting

Gray RAL-7016, Orange Glossy HGS 2302

RAL Colour

CE, ISO 9001, OSHA, UL

Certifications

Product Gallery

Powered Roller Conveyor Gallery 3.webp
Powered Roller Conveyor Gallery 4.webp
Powered Roller Conveyor Gallery 5.webp
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Powered Roller Conveyor Gallery 1.webp

Conveyor Sub Systems

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Chain Lift.webp
screw-lifter.webp
BELT LIFTERS.webp
Flipping Unit.webp
30° POP UP DIVERTER UNIT (PMD).webp
90° POP UP BELT DIVERTER UNIT.webp
TILTING UNIT.webp
TILTED GATE UNIT.webp
SWING WHEEL SORTER.webp
SWING ARM UNIT.webp
90° CHAIN DIVERTER UNIT (MCD).webp
90° POP UP BELT DIVERTER UNIT (1).webp
TURNOVER DEVICE TOD.webp
90° WATERFALL CHUTES.webp
90° POPUP DIVERTER UNIT (MPD).webp
90° CHAIN DIVERTER UNIT (MPD).webp
TURNTABLE UNIT.webp
CONVEYOR SUB SYSTEM.webp
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