Scarlett Barnes

Application of Gravity Conveyor in the Warehouse

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Gravity conveyor in a modern warehouse

Efficiency is one of the top priorities in the world of warehouse logistics. One widely used tool for streamlining operations is gravity conveyors. These systems rely on the power of gravity to move items rather than motorized sources. Simple, versatile, and cost-effective, these conveyors are indispensable in a variety of warehouse applications. 

Distribution Centers

In these facilities, large volumes of goods often need to be sorted, packed, and shipped quickly. Gravity conveyors can provide seamless movement of products at a couple different points of contact. Foremost, they are highly effective when placed at loading docks, especially flexible gravity conveyor, to help move products to and from trucks. Their simplicity and durability make them ideal for handling consistent traffic in high-demand zones. Likewise, they are useful in order-picking operations as they increase the speed by which employees can move products from storage to packing stations. Thus, gravity conveyors can reduce the workload put on employees and improve productivity. 

Manufacturing Warehouses

In manufacturing, material handling systems are often required to be robust and durable. They need to smoothly transport products at various stages of assembly and need to be adjustable for product staging and accumulation. Gravity conveyors are the flexible logistical answer to many of these situations.

These systems can be designed to handle items at all stages of production–raw material, work-in-progress, and fully finished goods–as well as a wide range of product weights and sizes. In terms of assembly lines, gravity conveyors can assist in the smooth transition of products between workstations and can be used to accumulate and stage products prior to the next assembly phase. This can smooth production and increase workflow. Overall, gravity conveyors play a key role in the stop-and-go, variable environment of manufacturing. 

Cold Storage Facilities

Gravity conveyors can help negate a lot of the challenges temperature-controlled warehouses face. Often, these facilities have higher operational costs due to increased utilities and the need for specialized equipment. Gravity conveyors have low start-up costs, do not rely on electricity, and already function well in sub-zero environments–overall helping keep costs low. These systems also increase the speed at which items move through the facility, reducing the time products are exposed to fluctuating temperatures, thus helping maintain the product’s integrity.

Lastly, due to their simplistic design, gravity conveyors require little maintenance and are highly reliable. This makes them low risk for mechanical failures and helps ensure consistent material flow with little delays. These factors make gravity conveyors an ideal tool for cold storage facilities that are looking to increase their productivity and keep operational costs low.

Future Trends

As warehousing evolves with the adoption of automation and integration, gravity conveyors remain relevant as a complement to these powered systems. Hybrid conveyor systems, combining gravity and motorized sections, are gaining in popularity. Utilizing sections of nonmotorized solutions, such as gravity conveyors, can help improve energy efficiency and allows warehouses to create customizable layouts to optimize their space and workflow. Even as businesses expand and advance, gravity conveyors can continue to be used–making them a long-term asset. 

Versatile and simple, gravity conveyors are a vital resource in the handling of materials across many industries. As businesses continue to seek sustainable and adaptable systems, the demand for gravity conveyors is predicted to grow. At SJF, our solution specialists are well versed in the application of these systems and understand the benefits they provide to our customers. 

If you have questions, want to receive more information, or would like a quote you can contact SJF’s Solutions Specialists at support@sjf.com or by calling 320-485-4974.

This is Part 3 of Our Series on Gravity Conveyor

Part 1: Effortless Efficiency: The Role of Gravity Conveyors in the Modern Warehouse
Part 2: Utilizing Slope and Load for Optimal Gravity Conveyor Performance
Part 3 (current): Application of Gravity Conveyor in the Warehouse

More Information

If you have questions, want to receive more information, or would like a quote you can contact SJF’s Solutions Specialists at support@sjf.com or by calling 320-485-4974.

Utilizing Slope and Load for Optimal Gravity Conveyor Performance

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Boxes on a gravity roller conveyor

Gravity conveyors are widely used in warehouse logistics to move products smoothly and efficiently without the need for external power. Cost-effective and low-maintenance, these systems are easy to implement and customize. In order to ensure efficiency and maximize productivity, two factors must be considered when implementing a gravity conveyor system: slope and load.

Determining Slope

The primary function of slope is to harness the power of gravity in order to move materials. Installing gravity conveyors to the proper slope is essential for ensuring the products move in a consistent and controlled manner – without stalling or excessive accelerations. 

At a minimum, slope angle for most gravity conveyors begins at 5°. However, the correct incline angle depends on several factors, including product load, flow control, and conveyor type. Roller and skatewheel are the two main types of gravity conveyor and their incline requirements differ: skatewheel conveyor systems typically need less slope than roller systems, since the wheels require less force to initiate movement. Similarly, the flow and layout of the facility are important to consider. Incline requirements will change depending on the length and height of the conveyor system, as well as if there are any curves or leveling points as they reduce flow. Lastly, the desired outcome of the product must be factored in. For example, if the desired flow is to allow products to accumulate at the terminal point, then more slope will be required.

In order to fine-tune slope angles, operators can adjust the supportive stands and brackets as needed. This allows for flexibility and ensures the system can be effective across a wide range of applications. For proper setup, consider using adjustable gravity conveyor stands & supports to modify the incline and ensure smooth product flow.

Factoring in Load

Load refers to the products being transported on the conveyor system. Item specifications that need to be considered include weight, shape, and packaging material. 

Weight: Heavier items often need a gentler slope since their greater weight builds momentum, causing the items to move quicker. Conversely, lighter loads typically require more slope.

Shape: Determining the product length to height ratio is important, as taller products are prone to tipping. Similarly, irregularly shaped items can often be more difficult to move, and thus require different slope considerations.  

Packaging: The way products are packaged plays a significant role in how they will move along the conveyor system. Surface characteristics–such as whether the packaging is rigid or flexible–friction levels, weight distribution, and the overall size and shape of the packaging must be considered as the variables can either accelerate or slow down the transport process. Below is a general guide as to how much slope is recommended based on packaging material:

These characteristics will also help determine what type of gravity conveyor is best suited for the items being moved. Skatewheel loads typically need to be lightweight and have a smooth, solid surface. Rollers can accommodate heavier, irregularly shaped loads more effectively.

Balancing Slope and Load for Optimal Performance

Calculating the proper slope takes trial and error. When implementing gravity conveyor systems, the slope should be well tested prior to full operation, as the required slope may differ from initial calculations. Since gravity conveyors are simple and flexible systems, they can be easily adjusted until the product flow is optimized. As products, packaging, or environments change, these systems can be further adjusted to account for any of these variables. 

Understanding the interplay between slope and load is critical in optimizing product line efficiency. Solution specialists at SJF are well versed in determining and carefully calibrating proper slope to ensure their clients systems are executed effectively. For businesses looking to maximize efficiency, custom gravity conveyor solutions and system design can help tailor conveyor setups to specific operational needs. When done properly, gravity conveyors provide an efficient, reliable, and safe solution for material handling.

This is Part 2 of Our Series on Gravity Conveyor

Part 1: Effortless Efficiency: The Role of Gravity Conveyors in the Modern Warehouse
Part 2 (current): Utilizing Slope and Load for Optimal Gravity Conveyor Performance
Part 3: Application of Gravity Conveyor in the Warehouse

More Information

If you have questions, want to receive more information, or would like a quote you can contact SJF’s Solutions Specialists at support@sjf.com or by calling 320-485-4974.

Effortless Efficiency: The Role of Gravity Conveyors in the Modern Warehouse

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Gravity Conveyor

Gravity conveyors have had a long-standing presence in warehouse logistics, and for good reason. These easy-to-implement systems are not only affordable, but are also versatile across many different industries without the need for mechanical power. Starting in January 2025, SJF will be an official supplier of Roach Conveyors – one of the leading American-made manufacturers of gravity conveyors. This article will cover the basics of gravity conveyors – how they work, their application, and the benefits in hopes that it can help you determine if this is the right type of system for your company’s needs. 

How Gravity Conveyors Work

A gravity conveyor is a non-powered material handling system that moves product using the natural force of gravity. Slope is key in the design and functionality of the overall system. Most systems are designed with a slight decline that is dependent on the product type, product weight, and system length. Flat systems can also be developed using a person pushing the material as the momentum to help the product slide down the line. 

There are two main types of gravity conveyor styles: Roller and Skatewheel

Gravity roller conveyors use tube-like cylinders that rotate so that items can pass over them freely. They come in a wide variety of materials and diameters, making them customizable for anything from light to heavy duty items. To ensure proper support and movement, systems should be designed with a minimum of three rollers under the product at any given time. 

Gravity roller conveyor photo

Gravity skatewheel conveyors use individual wheels mounted on axels to allow smooth product movement. They can be designed with a variety of different materials, but are best suited for lightweight applications. To ensure proper support and movement, systems should be designed with a minimum of 10 wheels under the product at any given time. 

Gravity skatewheel conveyor photo

Application

There are a variety of industries that can benefit from the implementation of gravity conveyors, including fulfillment centers, manufacturing, and even cold storage. These systems can handle a wide array of loads from light to heavy – especially if the items have a firm flat bottom, such as cartons, totes, cases, skids, drums, and more. Gravity conveyors are also flexible and adaptable for a multitude of uses, including production, distribution, shipping and receiving, as well as assembly lines. These conveyors can be installed with different specifications. Their sizes, lengths, widths, heights, and material can all be altered, as well as their method of mounting. They can be mounted on the floor, supported by stands, or even installed in rack systems. All of this together allows for complete customization, tailored to your company’s needs. 

Benefits

Overall, gravity conveyors are a simple and cost-effective solution to warehouse logistics that can provide a number of benefits. 

  • Minimal Investment: Since they rely on gravity there is no need for expensive motors or increased electricity usage. They are easy to install and operate, which keeps start-up and training costs low.
  • Efficiency: Gravity conveyors allow for a swift movement of product with minimal human intervention. This simplifies the workflow, reduces delays, and enhances productivity. 
  • Maintenance: These systems are incredibly easy to maintain. Since there is no motor there is a low risk for mechanical breakdowns. They are made of simple parts that are durable (usually aluminum or steel), easy to clean, and easy to replace.  If parts do break, replacements are typically accessible and made out of affordable material, rarely requiring professional service to fix. 
  • Ergonomic Improvements: Employees also receive benefits from the advent of gravity conveyors. They reduce the need for manual lifting and carrying, which in turn reduces injury risk and worker fatigue. Overall, this makes for a safer work environment.

As the demand for efficient material handling solutions grows, adoption of gravity conveyors is expected to rise. These systems are an economical way to quickly optimize your warehouse logistics while providing a number of additional benefits to the overall operation.

We at SJF recognize the value that these conveyor systems bring to our clients and are proud to offer new gravity conveyor and used gravity conveyor solutions, as well as system integration services for warehouse design and implementation. We’re excited to collaborate with Roach Conveyor and other leading vendors to provide high-quality products that meet our customers’ needs — now and in the future.

If you have questions, want to receive more information, or would like a quote you can contact SJF’s Solutions Specialists at support@sjf.com or by calling 320-485-4974.

This is Part 1 of Our Series on Gravity Conveyor

Part 1 (current): Effortless Efficiency: The Role of Gravity Conveyors in the Modern Warehouse
Part 2: Utilizing Slope and Load for Optimal Gravity Conveyor Performance
Part 3: Application of Gravity Conveyor in the Warehouse

More Information

If you have questions, want to receive more information, or would like a quote you can contact SJF’s Solutions Specialists at support@sjf.com or by calling 320-485-4974.