Improving Your Material Handling and Fabrication with Automation

paint finishing system

The assembly line, for many businesses, is the heartbeat of operations. From manufacturing to packing and distribution, the process of moving materials and products smoothly is crucial. With the advancements made in automation, your traditional material handling and fabrication solutions could benefit from an upgrade.

Enter Automation: Revolutionizing the Assembly Line

When you’re in the business of ensuring seamless operations, every minute and every movement matters. As the industrial world shifts towards a smarter, faster paradigm, automation stands tall as a beacon of efficiency. Here’s a more in-depth look at the many advantages of automating your material handling processes:

1. Flow-through Operation Process:

    • Efficiency at Its Best: Conveyor chain applicationsare meticulously designed to smooth out the kinks and quirks of material movement. The result? Reduced bottlenecks that can otherwise hamper productivity.
    • Consistency Guaranteed: Unlike manual processes which can be inconsistent, these systems guarantee a steady, unbroken flow of products. The outcome is a more predictable and streamlined operation, reducing both downtime and wasted resources.

2. Automated Controls:

    • Real-time Adaptability: Traditional systems demanded constant monitoring and manual adjustments. Today’s automated controls self-adjust in real-time based on system feedback, ensuring optimal performance without the need for human intervention.
    • Data-Driven Decisions: These systems often come with analytics capabilities, allowing operators to make informed decisions based on real-time data. This translates to proactive problem-solving and continual optimization of the workflow.

3. Robotics:

    • Precision is Key: Robotic finishing systems and robotic overhead conveyor systems are synonymous with accuracy. Every movement is calculated and precise, ensuring that errors are minimized.
    • Labor Efficiency: The integration of robotics dramatically reduces the reliance on manual labor. This doesn’t just lead to productivity improvement and cost savings but also mitigates risks associated with manual handling, especially in processes involving hazardous materials or conditions.
    • Scalability: Robots can easily be reprogrammed to handle different tasks, allowing businesses to adapt and scale their operations with relative ease.

4. Overhead and Side-by-side Conveyors:

    • Space-Savvy Design: Overhead chain conveyors and the innovative twin-trak side-by-side conveyor are game-changers when it comes to utilizing vertical space. This is especially beneficial for facilities with limited floor space, enabling them to handle more materials without expanding their footprint.
    • Versatility in Action: These systems can be tailored to handle a wide range of materials, from delicate items to heavy-duty products. With options to customize based on weight, size, and type of materials, businesses can ensure that their specific needs are met.
    • Reduced Ground Interference: By moving materials overhead, these conveyors also reduce the chances of ground-level obstructions or accidents, ensuring a safer environment for workers.

In a nutshell, automation in material handling is not just about embracing modern technology—it’s about proactively positioning your business for consistent growth, unparalleled efficiency, and a safer working environment.

A real-life testament to the power of automation can be found in a case study involving DeGeest Corporation. Our team at Richards-Wilcox Conveyor crafted a custom automated liquid finishing system, leveraging both paint finishing systems and robotic technology, transforming DeGeest’s operations. The result? Enhanced productivity, safety, and quality.

Harnessing the Power of Industry 4.0 with Richards-Wilcox Conveyor

As the wheels of Industry 4.0 set into motion, there’s a palpable shift in the winds of the material handling sector. Richards-Wilcox Conveyor, with our century-long legacy, recognizes the promise of this revolution and is at the forefront of integrating its principles into our state-of-the-art conveyor systems and solutions.

Smart Systems, Streamlined Operations: Richards-Wilcox Conveyor doesn’t just build equipment; we design intelligent systems for your operational needs. Here’s how we are weaving the fabric of Industry 4.0 into our offerings:

  1. 1. Predictive Maintenance: Our conveyor systems, equipped with advanced sensors, aren’t just about movement. They’re about proactive care, alerting you to potential maintenance needs, ensuring minimal downtime, and maximizing equipment lifespan.
  2. 2. Data-Driven Insights: Our automated solutions not only optimize material handling but also provide actionable insights. By analyzing this data, businesses can pinpoint inefficiencies, making informed decisions and strategies for future growth.
  3. 3. Seamless Integration: At Richards-Wilcox Conveyor, we understand the need for synchronized machinery on the production floor. Whether it’s integrating a robotic overhead conveyor system with packing and distribution or creating custom material handling solutions, our designs ensure that every piece of the puzzle fits perfectly.
  4. 4. Remote Operational Excellence: Our conveyor systems are designed for the modern age. Managers and stakeholders can monitor, assess, and even control systems from a distance, ensuring that operations remain smooth even in the face of unforeseen challenges.
  5. 5. Future-Ready Manufacturing: With the agility and adaptability embedded in our systems, businesses are not just prepared for today but are future-ready. As market demands shift, our systems offer the flexibility to evolve, ensuring that you remain at the cutting edge of your industry.

In essence, with Richards-Wilcox Conveyor by your side, you’re not just adopting new machinery; you’re embracing a future where your material handling processes are smarter, faster, and more adaptive. Let’s journey into this new era of efficiency and innovation together.

Richards-Wilcox Conveyor: Pioneering the Future of Automation

At Richards-Wilcox Conveyor, our focus is not just on selling equipment. We believe in crafting custom conveyor solutions tailored to your unique challenges. Our offerings range from custom material handling designs to robotic integration, overhead conveyor applications, and much more.

Remember, in the world of industrial material handling equipment, there’s no one-size-fits-all. But with Richards-Wilcox Conveyor, you’re guaranteed a solution crafted with your needs in mind, ensuring your assembly line remains efficient, reliable, and ahead of the curve. Let’s get started.

How to Choose the Right Paint Finishing System for Your Operation

paint finishing system

Selecting the right paint finishing system is akin to setting the foundation for a building. The right choice ensures operational efficiency, cost-effectiveness, and a flawless finish that meets industry standards. On the other hand, a misstep can lead to inefficiencies, increased operational costs, and inconsistent quality. With diverse options available in the market, how do you determine which paint finishing system aligns with your needs?

In this guide, we’ll navigate the various considerations essential for this decision-making process, ensuring you choose a system that enhances your operational prowess. With a legacy of pioneering solutions for complex operational challenges, our team at Richards-Wilcox Conveyor brings a wealth of knowledge and experience to the table, ensuring you have all the insights you need to make an informed decision.

Understanding Your Needs: Key Considerations in Selecting a Paint Finishing System

  1. Complexity of Your Finishing Process: Begin by assessing the intricacies of your finishing requirements. Do you need multiple coating layers? Are there specific drying or curing times for each?
  2. Available Space: The physical space you have will determine the type of conveyor and finishing system you can accommodate. Some systems require more overhead or floor space than others.
  3. Finishing or Treatment Process: Depending on whether you’re looking for dip, powder, spray paint, or electrocoating, your system requirements will vary.
  4. Size and Weight of Parts: The dimensions of the components you’re coating will influence the strength and design of your conveyor system. Larger, heavier parts might need more robust conveyor chains or trolleys.
  5. Material Type: The material of the parts you’re coating can determine the pre-treatment required and the type of paint or finish suitable for best adhesion and results.
  6. Flexibility: Do you foresee changes in your product line or finishing requirements in the near future? If so, opting for a system that offers flexibility will be essential.
  7. Part-Tracking Options: Consider how you’ll track parts through the finishing process. This can influence conveyor design and the necessary control systems.
  8. Connections: The manner in which trains, trolleys, and other components connect can influence the efficiency and speed of your finishing process.
  9. Sustainability: If environmental considerations are vital for your operation, options like powder coating, which is notably more sustainable, might be your go-to.

Exploring Richards-Wilcox Conveyor Solutions

Choosing the right conveyor system significantly amplifies the efficiency of your paint finishing process. At Richards-Wilcox Conveyor, we have crafted systems tailored to various operational needs:

  • Monorail Systems: The Efficient Choice
    • Zig-Zag Enclosed Track Conveyor: Ideal for simple operations aiming for cost efficiency.
    • Inverted Zig-Zag Conveyor: Offers the sturdiness of the Zig-Zag but with an inverted design for specific spatial requirements.
    • Safe-Rail Monorail Enclosed Track Conveyor: Combines efficiency with safety, ensuring seamless operations.
  • Power and Free Systems: Flexibility at Its Best
    • Twin-Trak Side-by-Side Conveyor: A dual-track solution perfect for operations seeking adaptability.
    • Over-Way Heavy Duty Over & Under Conveyor: Built for demanding environments where both power and flexibility are paramount.

Remember, integrating more automation into your conveyor system naturally bolsters its efficiency and adaptability, making your entire operation more streamlined and effective.

Navigating the Maze of Paint Applications: Which One is Right for You?

Deciding on the perfect paint application method for your operations can often seem like a daunting task. The application type you choose can directly influence the finish, durability, and overall quality of the product. Let’s delve into the prominent paint application types to help you make an informed decision:

1. Dip Coating:

  • What it is: Immersing the part into a tank containing the paint or finish.
  • Best for: Uniform coatings and parts with intricate designs.
  • Considerations: Requires space for dip tanks and may necessitate extended drying times.

2. Powder Coating:

  • What it is: Applying dry powder to a part electrostatically, followed by curing under heat.
  • Best for: Durable finishes and enhanced sustainability.
  • Considerations: Equipment for electrostatic application and curing ovens are necessary.

3. Spray Painting:

  • What it is: Utilizing a sprayer to apply paint in a fine mist.
  • Best for: Quick applications and parts of varying sizes.
  • Considerations: Requires proper ventilation and can result in paint waste.

4. Electrocoating:

  • What it is: A method where parts are dipped into a paint/water solution and paint is deposited electrochemically.
  • Best for: High-quality finishes and intricate parts.
  • Considerations: Needs electrical setups and specialized tanks.

Your choice will significantly depend on the material type, desired finish, and available resources. It’s also crucial to consider the integration of this application method with your conveyor system.

A harmonious synergy between the two ensures a smoother, more efficient finishing line. Whether you’re inclined towards a traditional paint method or looking to explore a robotic finishing system, Richards-Wilcox Conveyor stands ready to assist in integrating your chosen method seamlessly with our state-of-the-art conveyor systems.

Assessing Infrastructure and Adaptability: Ensuring Future-Proof Operations

As the business environment changes, so do the demands on your paint finishing systems. Investing in infrastructure that can evolve and adapt is not just a smart move, it’s essential. Here’s what to consider:

1. Space Utilization:

  • Overview: Efficient use of available space can significantly impact your operations, especially if expansion is on the horizon.
  • Our Solution: Our use of floor-mounted and overhead conveyor systems ensure optimal use of space, allowing for growth without major overhauls.

2. System Scalability:

  • Overview: A scalable system can grow with your business, accommodating increased volumes and new product lines.
  • Our Solution: Our conveyor systems design emphasizes modularity, letting you add or reconfigure components as your needs change.

3. Technological Integration:

  • Overview: In the era of Industry 4.0, integrating advanced technologies, like robotic interfaces, into your finishing line is vital.
  • Our Solution: We offer solutions that seamlessly integrate with both traditional and advanced robotic finishing systems, ensuring you stay at the forefront of innovation.

4. Sustainability and Environmental Concerns:

  • Overview: With increasing environmental regulations and a push for greener operations, having a sustainable system is crucial.
  • Our Solution: Our focus on solutions like powder coating underscores our commitment to sustainable and environmentally-friendly options.

5. Ease of Maintenance:

  • Overview: Downtime can be costly. A system that’s easy to maintain ensures consistent operations and reduced interruptions.
  • Our Solution: All our conveyor systems utilize our high-performance conveyor chain, which is the strongest and most reliable product of its time.

With Richards-Wilcox Conveyor’s breadth of options and custom solutions, you’re not just investing in a system for today, but partnering for a future of continued success.

Crafting the Optimal Path Forward

Choosing the right paint finishing system is more than a mere operational decision. It’s about sculpting the trajectory of your business, ensuring not only immediate efficiency but also long-term growth and adaptability. The myriad considerations — from the type of paint application to system flexibility and part tracking — each play a pivotal role in defining the success of your finishing line.

With Richards-Wilcox Conveyor by your side, you’re not merely getting a product; you’re gaining a partner with over a century of experience, expertise, and a commitment to excellence. By leveraging our comprehensive solutions, you’re setting your business on a course towards heightened efficiency, unrivaled quality, and unparalleled operational success.

In an evolving industrial landscape, the decisions you make today pave the path for tomorrow. Ensure your choices are informed, strategic, and backed by industry-leading expertise. Your business deserves nothing less.

bar code readers

Too Hot to Handle: Why Metal Barcodes are Perfect for High Temps

bar code readers

Carrier identification systems are the unsung heroes of the modern production line. While most of the Industry 4.0 hype is reserved for robotics and automation, none of these amazing technologies would be quite so effective without IDs and ID readers.

ID systems are at the heart of a smart facility’s internal communications. As carriers travel along a conveyor, IDs signal a unique fingerprint for each one, allowing various machines across the system to “know” where carriers are positioned at any given time. They make it possible for items to move through the same system in unique ways, signaling their presence and ensuring they undergo the right processing at the right time.

ID systems are essential to the modern production line. But finding the right system for your line depends on several key factors.

Heat might be the most important one.

When Radios Break a Sweat

One of the most common ID systems is Radio Frequency Identification (RFID). RFIDs signal a carrier’s unique “fingerprint” via radio waves, making them popular for applications that require individual control of each carrier after leaving the load point.

And yet, for all their strengths, RFIDs have a key weakness.

They just can’t take the heat.

Subject an RFID system to temperatures exceeding 300F, and something starts to happen. They become unreliable. Their signals are scrambled. Sometimes, they stop working altogether.

That might not be a problem for you, so long as temperatures along your line stay relatively low. But many applications – particularly finishing lines, which use ovens to cure parts – subject carriers to temps well over 300F. At the same time, they still need an identification system.

Fortunately, there’s one that can handle the heat.

The Beauty of Metal Barcodes

Metal barcodes might sound a bit low-tech. But they can be the perfect solution for power & free conveyor systems that subject carriers to intense heat. (And, as you’ll see, they’re hardly low-tech.)

The beauty of metal barcode plates is that they are specifically designed to withstand the hottest conditions. Cranking up an oven to 350F? No problem. Metal barcodes can even handle temperatures exceeding most conveyor warranties (up to 450F, generally).

But what about dirt and dust? As you may have heard, some barcode systems have a hard time operating in dirty conditions. As particles collect in the gaps between their bars, lasers struggle to read their codes, defeating the whole purpose of the identification system and, at times, causing damage and downtime. Some barcodes are as vulnerable to particulate as RFIDs are to heat.

The metal barcodes that we use at Richards-Wilcox Conveyor don’t have that problem. Thanks to the plates’ extra-large openings, lasers can easily read them, even when a large amount of dust collects on the plates themselves.

Finding the Right ID System

So which is better: RFIDs or metal barcode plates and readers?

As usual, there’s no cookie-cutter answer. It all comes down to your facility, your applications, and the conditions in which your conveyor is operating. The important thing is that you equip your line with the right ID system for your line.

That’s where we can help.

How Richards-Wilcox Conveyor Can Help You Evolve

From designing conveyor solutions for new facilities to integrating Industry 4.0 technology into existing lines, Richards-Wilcox Conveyor helps you create a smarter, faster, safer and more efficient operation—one that’s ready to compete today and evolve for the rapidly changing world of tomorrow.

Learn more about our legacy of innovation or get in touch with Richards-Wilcox to learn what we can do for you.

Key Benefits of a Conveyor Control System

5 Tips for Maximizing Your Manufacturing Space

maximize manufacturing space

In today’s fiercely competitive manufacturing landscape, maximizing space efficiency is critical to maintaining profitability and ensuring a smooth production process. One of the ways that forward-thinking manufacturers are accomplishing this is through innovative conveyor design and technology. Whether you’re just starting your manufacturing journey or looking to streamline an existing operation, understanding how to optimize your manufacturing space using conveyor design is a game-changer.

When it comes to space optimization, conveyor design plays a pivotal role. Not only can it help streamline your production process, but it can also significantly enhance your workspace’s overall functionality and efficiency. Here are some tips to help you make the most of your manufacturing space.

Tip #1: Evaluate Your Floor Plan

The first step towards maximizing your manufacturing space is to evaluate your current floor plan. Look for inefficiencies in your layout or workflow. For instance, are there areas where bottlenecks consistently occur? Are materials or products being transported over unnecessarily long distances or through convoluted routes?

For a real-world example of this tip in action, let’s look at the case of Eaton Corporation. Faced with the challenge of needing to optimize their manufacturing space, Eaton Corporation partnered with us to undertake a comprehensive evaluation of their floor plan. Through our collaborative efforts, we were able to identify and rectify several inefficiencies in Eaton’s previous layout. This resulted in a much more streamlined production process, increased safety, and better utilization of space.

The key takeaway here is that by understanding your floor plan’s shortcomings, you can make informed decisions about where conveyor chain applications would be most beneficial, leading to a more efficient and productive manufacturing environment.

Tip #2: Use Overhead Conveyors as a Space-Saving Solution

Overhead conveyors are not just a significant space-saving solution, but they are also a powerful tool for increasing the efficiency and safety of your manufacturing operations. This conveyor design lifts materials off the ground and utilizes the often-underused vertical space in a facility.

As opposed to traditional floor conveyors, overhead conveyors free up the floor space for other operations, movement of employees, or even additional machinery. This maximizes the use of available space and helps create a safer environment by reducing the risks of accidents that might occur due to congested floor areas.

Consider the benefits derived by Dematic Corporation when they introduced overhead conveyor technology into their manufacturing space. By working with us, they implemented an advanced zig-zag enclosed track conveyor. This new system allowed them to take advantage of unused vertical space and facilitated smooth operations. The result was a significant increase in their production efficiency and a safer, more ergonomic workspace.

Choosing the right type of overhead conveyor for your needs is crucial. A well-chosen system will maximize both the efficiency and the safety of your manufacturing operations.

Tip #3: Automate Processes

Automation is a crucial element in modern manufacturing, and when applied to your conveyor system, it can dramatically enhance your operational efficiency and save valuable space.

In an automated system, manual operations are significantly reduced or eliminated entirely. This means that you’ll require less space for workers to perform these tasks and can instead allocate this area for other purposes. Moreover, automated systems can work round the clock without the need for breaks or shift changes, leading to higher productivity.

The application of automation extends to different conveyor chain applications. Whether it’s sorting, assembling, packaging, or even quality control, automated conveyor systems can carry out these tasks with minimal human intervention. In addition, for finishing applications, automation allows for more accurate coverage and less processing time per unit, maximizing your output.

Remember, automating processes doesn’t mean that you will need fewer employees. Instead, it allows you to reallocate your human resources to areas where they can add more value, such as problem-solving and quality control.

Tip #4: Utilize Inclines and Curves

Incorporating inclines and curves into your conveyor design is another effective way to maximize your vertical manufacturing space. Straight conveyor lines can be limiting, particularly in a space-constrained environment. By introducing inclines and curves, you can navigate obstacles, utilize vertical space, and create a more flexible, efficient layout.

Inclined conveyor designs allow your conveyor system to move materials between different levels, enabling the efficient use of vertical space that might otherwise be wasted. Similarly, curved conveyors offer flexibility to navigate around obstacles, effectively using every inch of your available space.

For instance, if you have a pillar or other obstruction in the middle of your factory floor, instead of designing a conveyor system that bypasses this obstacle and takes up more room, a curved conveyor could easily navigate around it. This saves space and keeps your production lines running smoothly.

An excellent case study illustrating this point is Eaton Corporation. Through our work with them, they utilized a custom-designed curved overhead conveyor, maximizing their manufacturing space and circumventing any obstacles efficiently.

So, don’t let physical barriers limit your manufacturing capabilities. With inclined and curved conveyor design, you can leverage every nook and cranny of your manufacturing space to its fullest potential.

Tip #5: Consider a Custom-Designed Conveyor for Your Unique Challenges

No two manufacturing spaces are the same. Each one has its unique challenges and opportunities, making it essential to have a conveyor system tailored to your specific needs. A custom-designed conveyor can help you find the most efficient solution, with all the necessary twists, turns, inclines, and automations you may require.

Working with conveyor specialists, like our team at Richards-Wilcox Conveyor, can significantly improve your manufacturing space’s efficiency. They have the expertise and experience to create a conveyor design that not only meets your specific requirements but also maximizes your available space.

The Future of Manufacturing Space Utilization: Smart Conveyor Design and Technology

In an ever-evolving manufacturing landscape, it’s not just about fitting more into your available space. The future lies in intelligent design and technology – something that our team exemplifies.

Modern manufacturers are moving beyond traditional conveyor designs and adopting innovative systems to maximize space efficiency and productivity. From curved and inclined conveyors that navigate around obstacles and utilize vertical space, to automated systems that reduce manual tasks through robotic integration and boost output, there’s a vast range of possibilities available. However, choosing the right solution isn’t just about the technology itself, but also how it fits into your specific operation.

Our Final Thoughts

Space optimization is a critical component of efficient manufacturing operations. By evaluating your floor plan, implementing overhead conveyors, automating processes, and integrating inclines and curves, you can dramatically transform your manufacturing space. The addition of a custom-designed conveyor system further underscores the value of tailored solutions. As we move towards the future, embracing these innovative conveyor designs and technologies will be instrumental in propelling your manufacturing operations to new heights of productivity and efficiency. Reach out to our team to see how we can help you transform your manufacturing space.

The Sky’s the Limit: Unraveling the Benefits of Overhead Conveyor Systems

overhead conveyor zigzag

Imagine a world where products seem to float effortlessly through the air, navigating tight spaces and hazardous environments, all while increasing efficiency and reducing labor costs. Welcome to the fascinating world of overhead conveyor systems! These ingenious solutions have revolutionized industries such as food processing, pharmaceuticals, material handling, and industrial manufacturing. In this article, we will explore the advantages of overhead conveyor systems compared to other conveyor types and the industries they best serve.

Creating a Space Odyssey: The Art of Maximizing Usable Space with Overhead Conveyors

Overhead conveyors are the epitome of efficient space utilization. By making the most of vertical space, they free up valuable floor area for other essential operations, enabling businesses to optimize their production layouts and streamline their processes. This ingenious design helps companies enhance their facility’s overall productivity and increase output without having to invest in larger premises.

One of the most significant advantages of overhead conveyors is their ability to navigate tight spaces that traditional ground-based conveyor systems cannot. With overhead conveyors, products can be transported across multiple levels, taking advantage of the full height of a facility. This capability is particularly useful in industries with limited floor space or where the layout requires the conveyor to pass through areas with low clearance or around obstacles.

Moreover, overhead conveyors can effortlessly pass through areas that are inaccessible or hazardous to humans and robots, such as ovens, sprayers, or other hazardous environments. This feature allows for a continuous, uninterrupted flow of materials through the production process, reducing bottlenecks and minimizing downtime.

In addition to their space-saving benefits, overhead conveyors can be easily integrated with other equipment, such as automated sorting systems or robotic pick-and-place devices. This seamless integration further enhances the efficiency of the entire production line and reduces the need for manual handling of products.

Furthermore, overhead conveyors can be custom designed to accommodate the unique requirements of each facility, offering a tailored solution that maximizes usable space and meets specific operational needs. This flexibility allows businesses to adapt their conveyor systems to various product sizes, weights, and production volumes, ensuring that the conveyor system remains an effective and efficient solution even as their needs evolve.

A Safe Haven: How Overhead Conveyors Prioritize Safety in the Workplace

In today’s fast-paced industrial environments, safety is of paramount importance. Overhead conveyor systems are specifically designed with safety in mind, reducing risks and ensuring a secure working environment for employees. By eliminating clutter on the ground and keeping the products off the floor, overhead conveyors provide a safer and more organized workspace.

One of the most significant ways overhead conveyors prioritize safety is by providing employees with more space to work. With fewer moving parts on the ground, workers can move more freely and comfortably, reducing the likelihood of accidents and injuries. This additional space also enhances ergonomics, allowing employees to maintain proper posture and work more efficiently without straining their bodies.

Overhead conveyors minimize the need for human intervention in areas where there are dangerous risks, such as exposure to contaminants, extreme temperatures, or hazardous chemicals. By automating the transportation of products through these risky environments, overhead conveyors reduce employees’ exposure to potential hazards and help maintain a healthier work environment.

Additionally, overhead conveyors are designed with features that promote safe operation. For example, they often include guardrails, emergency stop buttons, and other safety devices that protect workers from potential harm. These safety features are crucial in preventing accidents and ensuring a secure workplace for everyone.

Moreover, overhead conveyor systems can be designed with enclosed tracks that protect both the products and the employees from dust, debris, and other airborne contaminants. This feature not only helps maintain product quality but also contributes to a cleaner and safer work environment.

The safety benefits of overhead conveyors extend beyond the immediate work area. By keeping the products off the floor and reducing the need for manual handling, these systems help prevent injuries related to lifting, carrying, and transporting heavy or awkward items. This reduction in manual labor not only contributes to a safer workplace but also helps companies minimize worker fatigue, boost morale, and reduce absenteeism due to work-related injuries.

Quality Meets Efficiency: The Perfect Harmony of Overhead Conveyor Systems

Overhead conveyor systems strike an ideal balance between maintaining product quality and enhancing efficiency throughout the production process. These systems are designed to optimize workflow, reduce waste, and minimize energy consumption, making them an excellent choice for businesses seeking to improve their bottom line while maintaining the highest quality standards.

One of the most significant benefits of overhead conveyor systems is their ability to adjust production rates according to demand. By incorporating advanced control systems and automation technology, these conveyors can be easily scaled up or down, ensuring optimal throughput and minimizing lead times. This adaptability is essential for industries that experience fluctuations in demand or need to accommodate seasonal changes in production.

Overhead conveyor systems are designed to minimize unnecessary manual transportation and rehandling of products, streamlining the entire production process. By eliminating the need for multiple material handling systems, businesses can reduce the risk of damage to products and minimize the chance of human error. This single, unified handling system ensures that products move smoothly and efficiently from one stage of production to the next, improving overall productivity and reducing the likelihood of costly delays.

Energy efficiency is another crucial advantage of overhead conveyor systems. These systems often consume less power than other conveyor types, thanks to their innovative design and use of advanced materials. For example, many overhead conveyors feature lightweight, low-friction components that reduce energy consumption and minimize wear on moving parts. This energy-efficient design not only lowers operating costs but also contributes to a smaller environmental footprint, making overhead conveyor systems an eco-friendly choice for businesses.

Furthermore, overhead conveyor systems can be customized to meet specific quality control requirements. For example, they can be integrated with automated inspection systems, ensuring that products meet exacting quality standards at every stage of the production process. This integration helps businesses maintain a consistent level of quality while increasing efficiency and reducing the risk of defects.

In addition to the quality and efficiency benefits mentioned above, overhead conveyor systems can also be tailored to accommodate various product sizes, weights, and shapes. This adaptability ensures that the conveyor system remains effective and efficient even as production requirements change or evolve, providing businesses with a long-lasting and future-proof solution.

Labor Cost Reduction Unleashed: The Power of Overhead Conveyors

In today’s competitive business landscape, controlling labor costs is a critical aspect of maintaining profitability and staying ahead of the competition. Overhead conveyor systems offer a powerful solution to this challenge, as they automate the movement of items throughout the production process, eliminating the need for manual transport and significantly reducing labor costs.

One of the key advantages of overhead conveyor systems is their ability to move products efficiently between various stages of production without the need for human intervention. By automating these tasks, businesses can save on labor costs by reducing the number of employees needed to handle product transportation, freeing them up to do work that can’t be automated or that requires human input, making the entire operation more productive.

Overhead conveyor systems also contribute to cost savings by reducing the likelihood of human error and product damage. With fewer workers involved in the handling and transportation of items, there is a lower risk of accidents or mishaps that can lead to costly delays, rework, or waste. This increased accuracy and reliability can result in significant cost savings for businesses over time.

Moreover, overhead conveyors can help businesses reduce their reliance on forklifts and other material handling equipment, which often come with high operating and maintenance costs. By minimizing the need for these costly resources, businesses can further reduce labor expenses and streamline their operations.

Industry Applications for Overhead Conveyors

The versatility of overhead conveyor systems makes them ideal for a wide range of applications and industries, including assembly lines, paint and coating processes, storage and retrieval systems, creative retail designs, and complex production setups. This adaptability allows businesses across various sectors to take advantage of the cost-saving benefits offered by overhead conveyors.

Industries that particularly benefit from overhead conveyor systems include automotive, leather, paper, food processing, garment, pharmaceutical, material handling, and industrial manufacturing. In these sectors, the ability to automate material handling processes and reduce labor costs is especially valuable, as it allows businesses to remain competitive and invest their resources in other value-added activities, such as research and development, marketing, or employee development.

Final Thoughts: Embracing the Overhead Conveyor Advantage

Overhead conveyor systems have revolutionized industries that value efficiency, safety, and cost reduction. By offering a unique combination of benefits, these systems are an ideal choice for businesses across various sectors, including automotive, leather, paper, food processing, garment, pharmaceutical, material handling, and industrial manufacturing.

Adopting an overhead conveyor system is not just an investment in technology, but also a strategic decision that can significantly impact your business’s success and sustainability. As industries continue to evolve and seek innovative solutions, overhead conveyors will play a crucial role in shaping the future of material handling and logistics.

Common Conveyor Design Mistakes and How to Avoid Them

assembly line customer support

In the fast-paced world of manufacturing and material handling, efficient and reliable conveyor systems are the backbone of countless industries. However, designing the perfect conveyor system can be a complex task, fraught with potential pitfalls that can negatively impact safety, productivity, cost, and the environment.

Today we’ll dive into the most common conveyor design mistakes and provide expert advice on how to avoid them. By understanding these critical mistakes, you can make informed decisions that optimize your conveyor system for long-term success, ensuring that your operation remains a well-oiled machine for years to come!

Mistake 1: Focusing on Up-front Costs Rather Than Lifecycle Costs

One of the most common mistakes when designing a conveyor system is basing the purchasing decision solely on the initial costs. While it’s important to consider the initial investment, it’s equally crucial to evaluate the life-cycle costs of the conveyor system. This includes ongoing maintenance, energy consumption, and potential downtime that could result from system failures.

By focusing on life-cycle costs, you can make a more informed decision and choose a conveyor system that offers a better return on investment in the long run. Richards-Wilcox Conveyor provides design services and expertise to help you evaluate the overall cost of a conveyor system and make the right decision for your business.

An excellent example of taking life-cycle costs into account can be found in the Dematic Corporation Case Study. By considering factors such as energy consumption, maintenance, and system longevity, Dematic was able to design a conveyor system that offered significant long-term savings and improved efficiency.

Mistake 2: Underestimating the Space Needed for Safe and Efficient Conveyor Usage

Another common mistake in conveyor design is underestimating the amount of space needed for safe and efficient operation. This can lead to issues such as insufficient access for maintenance, unsafe working conditions, and reduced efficiency. Examples of this mistake include using minimum pulley diameters and not providing enough clearance around the conveyor.

To avoid this issue, it’s essential to carefully evaluate the spatial requirements of your conveyor system, considering factors such as maintenance access, worker safety, and future expansion. Richards-Wilcox Conveyor can assist with spatial planning and design to ensure your conveyor system is both safe and efficient.

Mistake 3: Choosing the Wrong Materials

Selecting the appropriate materials for your conveyor system is crucial, especially in industries with strict requirements, such as food packaging and processing. It’s essential to choose materials that are compatible with the products being transported and meet any regulatory requirements.

To select the right materials for your conveyor system, consider factors such as the material’s form or state, flowability, composition, and particle size. Richards-Wilcox Conveyor has extensive experience in designing conveyor systems for various industries and can help you choose the best materials for your specific application.

Mistake 4: Selecting the Wrong Type of Conveyor

Choosing the wrong type of conveyor can lead to reduced efficiency, increased costs, and even safety hazards. It’s essential to select a conveyor system that is suitable for your specific application, taking into account factors such as material, operation, environment, space constraints, conveyor history, and cost. Moreover, it is important to consider the speed, load capacity, and durability of the conveyor system, as well as the ease of maintenance and potential for future upgrades.

There are numerous types of conveyor systems available, including belt conveyors, roller conveyors, chain conveyors, and pneumatic conveyors, each with their unique advantages and limitations. To help you choose the right type of conveyor for your industry, refer to our blog page for industry-specific advice and guidance. This comprehensive resource covers the specific requirements and challenges of various industries, from food processing to pharmaceuticals, and manufacturing to e-commerce, ensuring that you have the necessary information to make an informed decision.

With a wealth of experience and knowledge, our team can help you evaluate the pros and cons of different conveyor types and configurations, taking into account your specific needs, budget, and long-term goals. Through a thorough analysis of your operation, we can identify potential bottlenecks, inefficiencies, and safety concerns, offering solutions that optimize your conveyor system for maximum productivity, safety, and return on investment.

Mistake 5: Designing without Accurate Measurements

A successful conveyor design relies on accurate measurements of various factors, including weight, density, bulk load, speed, and angles. Designing a conveyor system without precise measurements can result in inefficiencies, increased costs, and potential safety risks, such as improper tensioning, inadequate load capacity, or incorrect incline angles that can lead to product spillage or damage.

To ensure your conveyor system is designed with the utmost accuracy, it is essential to gather comprehensive data on the materials being transported, as well as the environmental and operational conditions of your facility. This information will allow for precise calculations and informed decisions regarding the conveyor’s dimensions, layout, and component selection.

Working closely with experts can greatly benefit this process. Our team of experienced professionals can assist in obtaining the necessary measurements and data, guiding you through the various steps and considerations involved in designing a reliable, efficient, and safe conveyor system. Additionally, we can help you identify potential challenges or limitations related to your specific application, offering solutions that address these issues while maintaining optimal performance.

Mistake 6: Not Thinking Long-term

It’s crucial to think long-term when designing a conveyor system. A cost-effective and long-lasting conveyor solution should account for factors such as maintenance and expansion.

When considering maintenance, ask yourself if it will be easy to replace parts and keep the system running efficiently. For expansion, determine if the system you’re investing in has the capacity to be improved upon in terms of functionality and space as your operation grows.

By taking a long-term approach to conveyor design, you can ensure that your investment remains valuable and adaptable to the changing needs of your business without having to incur unnecessary costs down the road. Richards-Wilcox Conveyor can help you design a system that meets your long-term requirements while providing ongoing support and expertise as your operation evolves.

Mistake 7: Ignoring Environmental Factors

Environmental factors such as temperature, humidity, dust, and exposure to chemicals can have a significant impact on the performance and lifespan of your conveyor system. Ignoring these factors during the design process can lead to premature wear, system failures, and increased maintenance costs.

To ensure your conveyor system is designed to withstand the specific environmental conditions of your operation, work with experts like our team at Richards-Wilcox Conveyor. They can help you select the appropriate materials, coatings, and system components that will provide the necessary protection and durability.

Mistake 8: Overlooking Safety Features

Prioritizing safety is essential when designing a conveyor system, as it not only protects your employees but also contributes to the overall efficiency and productivity of your operation. Overlooking important safety features can lead to accidents, injuries, and even fatalities, as well as costly downtime, potential legal ramifications, and damage to your company’s reputation.

To create a safe and secure conveyor system, it is vital to incorporate a comprehensive set of safety features. These may include:

  1. Emergency stops: Ensure that easily accessible emergency stop buttons are placed at strategic locations along the conveyor, allowing for the rapid cessation of operation in case of an emergency.
  2. Guards: Install physical barriers such as guards and covers to protect workers from moving parts, pinch points, and other hazards.
  3. Warning devices: Implement visual and audible warning signals to alert workers of potential dangers or when the conveyor is about to start.
  4. Safety interlocks: Use safety interlocks on access doors and gates to prevent the conveyor from operating when opened.
  5. Fall protection: Install safety rails, platforms, and harness attachment points where necessary to protect workers from falls when performing maintenance or inspection tasks.
  6. Proper signage: Display clear and visible warning signs and labels to inform workers of potential hazards and safe operating procedures.
  7. Ergonomic design: Design the conveyor system to minimize strain and injury risk, considering factors such as workstation height, reach distances, and material handling requirements.

Consulting with experts can help you identify the necessary safety features for your specific application and ensure compliance with industry standards and regulations. Our team has extensive experience in designing conveyor systems with safety as a top priority and can provide guidance on implementing best practices to minimize risks and protect your workforce.

Mistake 9: Failing to Plan for Maintenance and Cleaning

Regular maintenance and cleaning are crucial for keeping your conveyor system running smoothly and efficiently. Failing to plan for these essential tasks during the design process can result in hard-to-reach areas, increased downtime, and higher maintenance costs.

When designing your conveyor system, consider factors such as accessibility for maintenance and cleaning, as well as the incorporation of features that facilitate these tasks.

Mistake 10: Not Engaging Stakeholders Throughout the Design Process

Lastly, the design of a conveyor system is not a one-person job; it requires input from various stakeholders, including operators, maintenance personnel, management, and safety officers. Failing to engage these stakeholders throughout the design process can result in a system that does not meet the needs and expectations of those who will interact with it daily.

To ensure a successful conveyor design that meets the requirements of all stakeholders, involve them in the planning and decision-making process. Experts can also assist in facilitating effective communication and collaboration among stakeholders to create a conveyor system that satisfies everyone’s needs.

By avoiding these common conveyor design mistakes and working with experienced professionals like our team at Richards-Wilcox Conveyor, you can develop a conveyor system that is safe, efficient, cost-effective, and environmentally friendly, ensuring the success of your operation for years to come.

A Deeper Look at Our Comprehensive Conveyor Customer Support System

assembly line customer support

The success of your conveyor operation relies heavily on a conveyor system that is dependable and efficient. Richards-Wilcox Conveyor is the go-to source for innovative conveyor system designs, high performance conveyor chains, conveyor controls and software solutions that make your manufacturing environment more productive and your organization more profitable. In addition, we provide an extensive customer support system to ensure client satisfaction every time.

Education & Training

Offering full training and education on your control system is a significant part of our design and installation services. Our instructional programs are designed to provide our clients with an understanding of industrial material-handling equipment, robotic interfaces, automation, and any other elements of your conveyor that are essential for successful operation within your industry.

We provide information to all staff on how to run and maintain your conveyor control system effectively, creating a smoother transition for your factory. Successful implementation of high-performing conveyor systems is contingent on flawless design and installation; however, we understand that ongoing support plays an equally crucial role in achieving sustainable success. Our adept professionals ensure expeditious responses to all customer inquiries and grievances while delivering access to educational resources and training programs aimed at optimizing business performance.

Customers choose us as a trusted partner because we go above and beyond supplying high-quality conveying equipment. We understand the importance of educating our customers about how their systems work at every stage of development from design through installation & operation until maintenance & troubleshooting stages, enabling them to reduce costly downtime whilst boosting overall efficiency (resulting in higher profitability).


Installing or enhancing a conveyor system is a huge investment in your business operations. Therefore, the concern of unanticipated design changes or installation challenges that would require rebuilding part of your system can cause a lot of financial anxiety. With Richards-Wilcox Conveyor simulations, you can see your conveyor in action before it exists! Numerous scenarios can be tested, processes can be analyzed and optimized to identify bottlenecks, and waste can be reduced to improve efficiency before a conveyor system is ever installed.

Our simulation experts use their in-depth experience and cutting-edge technologies and methodologies to model different design and installation options, providing you with knowledgeable insights based on real-time data analysis that aid in better decision-making and conveyor system design. Our advanced simulation tools can also be utilized to examine how your conveyor components, including the conveyor control system, perform under different loading conditions without inhibiting precision.

Simulation is a great way to plan an extension of your current conveyor as well. Seeing how the new addition to your system can seamlessly integrate with your existing system prior to installation is a game changer for Industry 4.0 and helps our customers keep their conveyor projects on time and on budget.


Businesses that are flexible and adaptable will have a strong advantage over their competitors as conveyor technologies continue to rapidly evolve. Reevaluating your operation on a regular basis to determine if improvements can be made through new technological breakthroughs is a way our support team can help keep your system ahead of your competitors and at its most effective. This process is called modernization.

When we collaborate with you on modernization, we will review the design of your current conveyor system, talk about your objectives, and create a strategy to achieve them. Our in-depth understanding of industrial material handling trends and technologies allow us to keep you ahead of the curve.

Maintenance & Parts Replacement

Richards-Wilcox Conveyor is not only a respected partner in new or expanding conveyor systems; we also provide top-notch solutions in conveyor system parts replacement and maintenance. To avoid having to worry about future costly repairs or unexpected shutdowns, our team can help you develop a maintenance schedule for your conveyor system. In addition, our specialists will evaluate your system and help you determine what replacement parts you may need, whether that’s a chain, belt, or anything in between. Finally, we provide thorough installation instructions and prompt delivery, to maintain (or enhance) your factory’s productivity and reduce downtime.

Ongoing Customer Support

Conveyor systems, like all technology, can have their hiccups. Therefore, we understand the significance of providing exceptional ongoing customer support. Our accomplished team has a vast knowledge of industrial material handling equipment, conveyor systems design, installation and more, which qualifies them as dependable sources of solutions for any potential problems for our clients. Our all-encompassing customer support ensures that every customer inquiry is handled effectively and efficiently. Client satisfaction is always our #1 goal.

Richards-Wilcox Conveyor Solutions

At Richards-Wilcox Conveyor, we boast a century of innovation, evolution, and craft, maintaining a finger on the pulse of conveyor system trends. We continue to lead our clients into the future by engineering the most effective conveyor solutions that have undergone intense conveyor simulation and testing.

We believe the conveyor system is the backbone of any operation, and it is our job to support your through the lifetime of your system. For more information on our systems and products, contact us.


powder coating

5 Tips for Maximizing Your Finishing Line: Conveyor Systems & Engineering

powder coating finishing line

As the world embraces Industry 4.0, manufacturing and distribution operations are becoming more streamlined and efficient. Finishing lines are no different, as automation revolutionizes the industry.

With so many moving parts in any operation, it’s important that the finishing line receives the same attention and strategy as the rest of the production and manufacturing process.

The Importance of the Finishing Line

Manufacturers need to be fast and lean to remain competitive in the current environment. A finishing line can be used for wet spray painting, powder coating, dip lines, cleaning and pretreatment, and more. As such a versatile element in your conveyor system, it is a large factor in how efficient your entire system is.

Conveyor belt technology is at the heart of these operations. These systems play a critical role in transporting products and materials from one point to another. When strategically operated, conveyor belt technology helps to increase productivity and optimize the distribution process.

Tips for Maximizing Your Finishing Line

With technology and the use of space in mind, consider the following top tips for maximizing your finishing line.

1.   Reduce material handling costs

Profit is the end goal in most businesses, and efficient finishing line conveyor systems help to boost profit by lowering expenses associated with material handling costs. Finishing line conveyor systems use automation to transport and sort materials, reducing manual labor costs for repetitive tasks.

Conveyor belt systems also help to free up space in the warehouse or factory by removing bulky storage solutions. Instead of relying on pallet racks and bins, conveyor belt systems use space efficiently, helping to reduce the demand for space and the overhead cost associated with it.

2.   Optimize conveyor design

Various finishing lines require different design elements. Make sure you choose the best finishing line conveyor system design to meet your needs. Whether you need large-scale robotics systems or simple paint line conveyors, it’s important to choose a system that offers flexibility, reliability, and customization.

For example, standard (monorail) systems are a simple and cost-effective solution for straightforward processes as the system follows a single path. These can be installed manually or by a continuous chain, such as safe-rail, zig-zag, or inverted zig-zag for batch paint systems. A chat with our expert team will guide you in the right direction.

Power & free systems are other options for finishing line conveyor systems. Overhead power & free conveyors offer flexibility to adjust to operational needs. With the option to operate at different speeds, divert to multiple locations, and provide part-tracking analytics, these systems are versatile and help to maximize the finishing line productivity.

3.   Incorporate automation

There are many different benefits to incorporating automation into your finishing line, all of which promote efficiency. Automation helps to reduce labor costs by training robots to perform mundane, repetitive tasks, freeing up manual labor that is better suited elsewhere. These robots work for longer hours with less risk of injury. Robots are reliable and consistent, producing fewer costly errors.

Robotic finishing systems use various tools and techniques to automate processes, saving time and money. For example, sensors and automated controls ensure that the conveyor system operates efficiently and that products are transported smoothly from one process to the next.

Consider how automated conveyors are revolutionizing paint applications. Automated paint finishing systems use robotic arms with servo motors integrated into conveyor systems, improving precision and flexibility. With sensors and robotics to assist the process, businesses experience less waste, greater flexibility, and improved production volume compared to manual capabilities.

4.   Think vertically

Conveyor systems are often thought of in horizontal terms, but they can be even more effective when installed vertically. Rather than rely on horizontal systems to move items along a flat plane, vertical systems send products up and down, efficiently using the space. Taking advantage of vertical space cuts down on expensive overhead linked to renting larger spaces.

Overhead conveyor applications utilize the open space above to transfer items and materials, freeing up valuable floor space and reducing the need for a possible expansion.

Vertical design can also be incorporated by rethinking vertical transport units (VTU). Innovative VTUs are supported on all four sides, resulting in a robust mechanical design. By using an electric servo to control the VTU positioning, the movement is smoother and quicker. Finally, the servo stops the conveyor deck more precisely at multiple positions, which assists with accuracy.

5.   Extend conveyor life

If you want to maximize your finishing line, you need to keep downtime to a minimum. One of the most effective ways to achieve this is to keep your finishing conveyor systems in tip-top shape. Wear and tear occurs in many ways, and maintenance is imperative.

To keep your conveyor on track, lubrication should be applied appropriately, a schedule of chain conveyor maintenance should be followed, and the manual should be studied to understand specific maintenance needs better. By conducting regular and preventative maintenance, the system will keep operating smoothly and keep pace with a radically changing world. Any questions on how to properly maintain your conveyor? We’re here to help!

Maximize Your Finishing Line with Richards-Wilcox Conveyor

At Richards-Wilcox Conveyor, we’ve created flexible, modular, and automated systems designed to last. Whether you’re looking for a standard monorail system for a simple process or a power & free system that offers unparalleled flexibility, we’ve got you covered.

If you’re ready to get started on a new conveyor project — or give an existing project an overhaul — we’d love to hear from you. Contact our team today!

2023 Trends in Conveyor Technology

zigzag conveyors

If you want to succeed in the world of Industry 4.0, then you need to adapt to the latest trends and create a fast, lean, and advanced system. At Richards-Wilcox Conveyor, we believe that efficiency begins with your conveyor technology.

Each year brings new trends, and it’s important to keep these conveyor technology trends in mind as you make adjustments to your existing system or start to design a new system. As experts in the industry, we’ve put together a few of the top trends for 2023, from robotic integration capabilities to energy efficiencies and safety design.

Energy Efficiency

As sustainability becomes an increasingly significant priority around the world, companies are investigating new ways to reduce energy consumption (and reduce material handling costs). One of the best ways to reduce the energy use of conveyors is by streamlining the mechanics used to operate these systems. Considering that modern conveyor systems are the backbone of your IoT infrastructure, it’s important to design your conveyor belt with connectivity in mind and integrate the system with the latest technology.

For example, conveyor systems equipped with motorized driven roller systems are more energy-efficient than legacy systems. These quiet systems can save companies up to 81% in energy use. Another way to improve power generation is to attach a mini-generator to idlers and take advantage of the kinetic energy created by the moving belt. Through magnetic coupling, the generators operate efficiently while ensuring that no electrical or mechanical overload occurs.

Building Vertical to Optimize Space

As business and demand grow, so does the need for space. However, waiting for building expansions or securing acquisitions can be time-consuming and expensive, or simply just not an option, causing companies to miss out on time-sensitive opportunities and profits. To meet this need efficiently and without breaking the bank, companies can utilize vertical space by using lifters and overhead conveyor systems.

By making the most of vertical space, companies save time and money and improve their productivity. For example, lifters are designed to move various loads from one level to another while vertical farming applications operate as overhead handling systems that optimize space.

Another way to optimize space in the warehouse is through conveyor rotation which offers an ergonomic solution to improve productivity and space.

Flexibility and Expandability

Depending on the business’s materials and end product, you may experience seasonal volume increases, unexpected spikes in demand, and opportunities to grow your brand. In these instances, it’s important to meet demand and increase production. Since the COVID-19 pandemic, we’ve seen many persisting logistics and supply chain issues that have made these shifts more common and the ability to adapt more important than ever. Expandable conveyor belts can be assembled and reconfigured to meet these shifting market demands.

Flexible conveyors allow businesses to adjust their output depending on the demand, ensuring orders are fulfilled without wasting materials or time. Expandable conveyors are an affordable alternative to fixed conveyors, allowing companies to adapt to new packaging designs, order sizes, product lines and other evolutions.

Prioritizing Speed

Competition between manufacturers and distributors over the past few years has intensified. As that continues into 2023, time is of the essence, and conveyor technology becomes a critical point for addressing the need for fast production. As requirements increase, manufacturers are searching for ways to optimize the speed of conveyor systems without compromising product quality or staff safety.

Much inspiration is taken from the airlines’ Interroll Portec systems which rely on speed and durability to handle materials in demanding environments, such as distribution and parcel handling operation centers. Considering that even marginal adjustments to speed can lead to unanticipated problems, businesses must invest in trusted systems that execute these adjustments with reliability.

Robotics & Automation

Robotic systems, especially in the finishing industry, are leading the charge in conveyor system design trends. Robotics are being used to integrate into conveyor systems to automate material handling, improve efficiency, and offer other robotic integration benefits. For example, autonomous mobile robots (AMR) help transport materials around a facility and robotic arms and end-effectors pick and place items on the conveyor. Robots work alongside human operators, often handling dangerous, dirty, or repetitive tasks, shifting the demand for manual labor to more complex tasks, making the human and robot more productive.

Another improvement in which allows machines to identify and track items on the conveyor with improved speed and accuracy. This development helps to reduce errors and increase output.

The continued migration to Industry 4.0 technologies has led to significant advantages such as real-time data analysis and enhanced productivity in automation. By collaborating and integrating horizontal and vertical systems, automated systems and robotics play an invaluable role in meeting productivity demands. Conveyor controls are adjusted according to need, and automated processes make sure jobs are completed on time and up to standard.

Examples of these automation technologies include radio frequency identification (RFID) and the previously mentioned AMRs. The benefits of automation vary depending on the specific function of each conveyor system.

Safety Design

Each conveyor system design comes with its own unique safety risks, which need to be considered and addressed carefully. For instance, higher belt speeds make pinch and sheer points of conveyor systems more dangerous. Addressing these risks through modern tracking technology and innovative designs reduces safety hazards. In the process, the cost of injury and damage is also reduced.

Maintenance is also key to safety, and conveyors and automation go hand-in-hand as conveyor systems autonomously operate to predict maintenance needs. For example, modern stilling zones are crafted with an innovative chute design to reduce the need for maintenance and improve safety. In another example, belt cleaner technology uses an automated system to increase blade life and belt health by removing contact between the blade and belt when a conveyor runs without materials.

Conveyor Systems Engineered for Evolution

At Richards-Wilcox Conveyor, we boast a century of innovation, evolution, and craft, maintaining a finger on the pulse of conveyor system trends. We continue to lead our clients into the future by engineering the most effective conveyor solutions that have undergone intense conveyor simulation and testing.

We believe the conveyor system is the backbone of any operation. Incorporating these trends of energy efficiency, space optimization, automation and robotic integration, and safety design ensures an optimal system. For more information on our systems and products, contact us online or call us at 888-852-1020.

distribution conveyors

Distribution Challenges and How to Increase Operating Profits

distribution conveyors

The modern conveyor system offers an efficient and cost-effective way to distribute goods in a variety of industries. Whether it be moving materials, packages, or parts, the right conveyor system helps you streamline production and minimize losses.

Yet as beneficial as conveyors are to productivity, there are some common challenges associated with them that can cause downtime and impact overall efficiency.

Let’s take a look at the most common issues customers experience with conveyors and explore some dynamic solutions that can increase operating profits while decreasing waste. As well as the benefits that come with implementing evidence-based solutions through Richards-Wilcox Conveyor – one of the leading industrial automation companies in North America.

The Top Conveyor Distribution Challenges and How to Solve Them

Conveyors are a vital part of the distribution system in many industries, but they can come with their own set of challenges.

1. Know Everything About What You’re Moving

In order to optimize the conveyor system, you need to know everything about what you’re moving. This includes the weight, size, shape, and fragility of the items you’re moving, as well as environmental factors such as temperature, humidity, and dust. Without properly accounting for all of these factors, your system may not be able to function correctly and could lead to costly repair and maintenance bills.

The Solution: To ensure the proper functioning of your conveyor system, you must take the time to understand the exact parameters of the items you’re moving. With Richards-Wilcox Conveyor’s advanced conveyor engineering, you can receive a custom-made conveyor solution tailored to the exact needs of your business.

2. Improper Maintenance or Lack of Maintenance

Proper maintenance is essential to keep any conveyor system running at peak performance. Unfortunately, many businesses fail to dedicate enough time and money to maintain these systems. This can lead to an inefficient system, as well as costly repairs and maintenance bills.

The Solution: Richards-Wilcox Conveyor’s maintenance programs are designed to help you get the most out of your conveyor system. Our team of experts can help you design and implement a maintenance program tailored to the specific needs of your business. This will help keep your system running smoothly and reduce downtime.

3. Inadequate Design

The design of your conveyor system is critical to its success. If the system is not designed properly, it can lead to costly repairs, inefficient operation, and prolonged downtime. These issues can have a major impact on your bottom line.

The Solution: The team of experienced engineers at Richards-Wilcox Conveyor can help you design the perfect conveyor system for your business. We will work with you to understand your specific needs and develop a system that is both cost-effective and efficient.

4. Dirty and/or Hazardous Locations

Contaminants and hazardous materials can wreak havoc on conveyor systems. These materials can cause corrosion, blockages, or even fires. This can lead to costly repairs and downtime, not to mention, they can be a danger to both you and your employees.

The Solution: An optimized industrial conveyor system from Richards-Wilcox Conveyor can help you avoid these dangerous and costly problems. Our systems are designed with the utmost safety and reliability in mind, and our team of engineers can help you customize a solution that meets your specific needs, even in the most challenging environments.

5. Poor Distribution Efficiency

An inefficient distribution system can lead to lost profits and damage your bottom line. If your system is not working correctly, it can cause slowdowns in production and delays in shipping and delivery. Inadequate inventory management can also lead to additional costs as you are paying for stock that isn’t moving.

The Solution: With Richards-Wilcox Conveyor’s automatic inventory management system, you can eliminate these problems and improve the efficiency of your distribution system. Our advanced technology can help you label, track, and trace all products, ensuring that the right items are shipped on time and minimizing the amount of stock you are carrying.

6. Timely Manual Processes

Manual processes can be time-consuming and require an operator to be constantly on hand. Automation is a great way to reduce manual processes. Automated systems can be set up to operate without a person present, and even identify areas of inefficiency and issue reports. When combined with advanced real time analytics, this can create a powerful, cost-effective solution for better tracking and accountability.

The Solution: Utilizing data-driven analytics and technology to identify areas of inefficiencies in manual processes can help reduce time and costs in the distribution system. An automated system can streamline the process and accurately monitor performance over time. Richards-Wilcox Conveyor offers a wide range of automated solutions and real-time analytics to make distribution more efficient and cost effective.

7. Lack of Visibility in Your Inventory

Maintaining accurate inventory tracking can be a real challenge. If inventory numbers are inaccurate or outdated, it can lead to unforeseen delays and costly mistakes. A lack of visibility also makes it difficult to identify damaged or missing items and effectively track inventory performances.

The Solution: Utilizing RFID technology can help increase visibility and accuracy in tracking inventory. RFID tags can be placed on each item, enabling real-time scanning and tracking. This data can be linked to analytics software for better visibility and tracking of inventory.

8. Lower Transport Efficiency

Lower transport efficiency can lead to longer delivery times, higher operational costs, and customer dissatisfaction due to inaccurate tracking. Having an efficient and cost-effective transport system is essential to any business, especially in the delivery of goods.

The Solution: Utilizing a conveyor-based system can significantly improve transport efficiency. With a wide range of options, Richards-Wilcox Conveyor can create an efficient, automated transport system that moves items through the distribution system quickly and accurately. This can help reduce operational costs and increase customer satisfaction.

Fortunately, there are several solutions that can help businesses address these problems. Dynamic solutions such as improved alignment techniques, upgraded support structures and updated components help ensure smooth operation while comprehensive training and preventive maintenance programs allow for better management of resources and increased productivity.

Implementing evidence-based initiatives like those offered by Richards-Wilcox Conveyor is also key; their advanced systems offer superior control over all aspects of conveyor operations including speed regulation, pressure monitoring and load balancing – ensuring optimal performance every time.

The Benefits of Implementing Dynamic, Evidence Based Conveyor Solutions

Dynamic, evidence-based conveyor solutions offer a range of benefits for businesses in any industry.

By streamlining production and minimizing losses through improved alignment techniques, upgraded support structures and updated components, conveyors can increase efficiency while decreasing downtime.

Through comprehensive training and preventive maintenance programs that address common issues like misaligned belts or worn-out parts, businesses can better manage resources and increase productivity.

Moreover, implementing advanced systems such as those offered by Richards-Wilcox Conveyor ensure superior control over all aspects of operations including speed regulation, pressure monitoring and load balancing – ultimately leading to faster completion times with fewer errors. By investing in dynamic solutions that are based on the latest research and technology trends available today, companies can enjoy greater cost savings while gaining an edge over their competitors when it comes to efficient distribution processes.

The Importance of Conveyor Solutions for Industries

Conveyor solutions have become increasingly important for industries across the globe to help them maximize profits and reduce costs. In today’s competitive market, every business needs to be able to move products quickly and efficiently. By implementing a conveyor system, businesses can quickly transport goods from one place to another without the need for additional labor or costly equipment.

Furthermore, these solutions can help businesses reduce waste and improve safety conditions. By using efficient systems that are tailored to each business’s needs, companies can better manage their inventories and reduce human error. Additionally, with advanced technology like RFID tagging, companies can quickly track goods and ensure that shipments are delivered on-time.

Finally, conveyor solutions can also help businesses meet consumer demands faster. By cutting down on manual operations and improving production accuracy, companies can better respond to customer demands and generate more revenue. Ultimately, implementing dynamic conveyor solutions are essential for modern businesses looking to stay ahead of their competitors.

Benefits of Investing in Dynamic Conveyor Solutions

Investing in dynamic conveyor solutions can benefit businesses in numerous ways. First and foremost, it can help them reduce costs and increase efficiency. Automated conveyors can be tailored to meet the specific production, packaging and distribution needs of a company, saving time, money and labor.

In addition, investing in dynamic conveyor solutions can help businesses improve safety conditions and reduce accidents. Through advanced sensors, automated shutoffs and emergency stop systems, companies can ensure that their operations are more secure and controlled.

Finally, by investing in dynamic solutions, companies can significantly reduce their environmental impact. By investing in low-energy conveyors and reducing the amount of paper and plastic used for packaging, businesses can reduce their carbon footprint while still meeting the demands of their customers.

Ultimately, the benefits of dynamic conveyor solutions are vast and varied, making them an ideal investment for businesses of any size or industry.

How Richards-Wilcox Conveyor Can Help You Increase Operating Profits

Richards-Wilcox Conveyor is a leading industrial automation company that can help you increase operating profits through their advanced systems. By investing in evidence-based solutions, businesses can enjoy greater cost savings while gaining an edge over their competitors when it comes to efficient distribution processes.

Modern shipping requires dynamic solutions designed to streamline production and minimize losses by improving alignment techniques, upgrading support structures and replacing worn-out or broken parts.

With advanced systems that offer superior control over all aspects of conveyor operations including speed regulation, pressure monitoring and load balancing, you get optimal performance every time.

With these modernized solutions, companies can save money on labor costs while maximizing profitability with fewer errors. In addition to increasing efficiency throughout the entire transportation process, Richards-Wilcox Conveyor also offers analytics capabilities which allow customers to gain valuable insights into operational data for further optimization opportunities.

Ultimately this allows businesses to make more informed decisions about how they run their operations – resulting in higher profits at lower costs!