In the competitive world of industrial manufacturing, efficiency on the assembly line can make or break a business. Streamlined processes lead to reduced costs, faster production times, and higher quality outputs. Leveraging modern conveyor technology and strategic planning can transform assembly line operations. Here are three key ways to maximize efficiency in your assembly line conveyor system operations.

1. Optimize Conveyor Design and Controls

The foundation of an efficient assembly line starts with thoughtful conveyor design and advanced control systems. Designed conveyor systems tailored to your operational needs ensure seamless integration with your facility’s layout and processes.

Start by analyzing your layout and create a path that connects load and unload areas with process equipment. This allows for smoother material flow.

Consider electrical characteristics, carrier spacing, and track elevations to boost safety and synergy between workers and carriers. A well-designed system minimizes the risk of bottlenecks and downtime.

Conveyor controls further enhance efficiency by providing real-time insights and flexibility. For example, graphical user interfaces (GUIs) allow operators to monitor production metrics, make quick adjustments, and coordinate with other departments. Advanced control systems also facilitate variable production rates and quick changes, enabling manufacturers to meet shifting demands. These features streamline operations to help analyze critical data and optimize future processes.

2. Upgrade Outdated Systems with Overhead Conveyors

Outdated conveyor track systems can significantly hinder efficiency, but upgrading doesn’t necessarily mean starting from scratch. Modern overhead conveyor applications—such as the Richards-Wilcox Conveyor’s Zig-Zag® Enclosed Track Conveyor—are designed to work within existing landscapes.

The Zig-Zag® conveyor’s modular design makes it adaptable and easy to install, modify, and maintain. Its ability to navigate tight curves and changes in elevation maximizes floor space and allows for higher productivity. Additionally, the system’s compatibility with power-and-free configurations ensures future scalability, making it a cost-effective solution for industrial manufacturing facilities.

Case studies highlight the impact of upgrading to modern overhead conveyors and beam conveyors. For instance, Premier Citrus Packers replaced an aging, inefficient overhead conveyor system with a Zig-Zag® overhead conveyor. The upgrade utilized the existing footprint, eliminating the need for extensive adjustments while drastically improving productivity and reducing downtime. Similarly, Dematic Corporation leveraged an overhead conveyor system to streamline tote delivery, automating loading and unloading processes for seamless integration with their roller conveyors.

These examples underscore the importance of selecting adaptable material handling equipment that can evolve with your facility’s needs.

3. Leverage Conveyor Rotation for Streamlined Operations

Small efficiencies can lead to significant improvements over time. Conveyor rotation is an innovation that enhances assembly line productivity by reorienting parts for easier handling and processing. Rotation systems, such as spinning pendants, allow parts to rotate 180 degrees, enabling ergonomic access for workers or robots. This reduces the need for additional handling and improves the overall flow of operations.

In facilities with limited space, conveyor rotation can be a game-changer. Rotation systems optimize floor plans and improve workplace ergonomics by allowing workers to operate from one side of the track.

Zig-Zag track conveyors provide different rotation options. These include free-spin pendants and powered rotators. The powered rotators activate at certain trigger points. These solutions enhance flexibility and efficiency in assembly line operations.

Maximize and Strategize

Boosting efficiency in assembly line operations requires a strategic approach to conveyor systems. From optimizing conveyor design and controls to upgrading outdated systems and leveraging innovative features, these solutions can transform your operations. Richards-Wilcox Conveyor’s products are crafted to meet the needs of material handling equipment manufacturers and industrial manufacturing facilities.

Advanced conveyor systems not only boost productivity but also position your business for long-term success. The right heavy-duty tools can increase efficiency and output, and Richards-Wilcox Conveyor is here to help.

If you’re like us, you’ve been dreaming about robots since you were a kid. In all the sci-fi movies, the robots (the good ones, anyway) made life easier for people. They did the work we didn’t want to do. Not only that—they worked harder, moved faster, and completed tasks with incredible speed and precision.

Today, the manufacturing industry is waking up to a world where those robot dreams have come true. Robots are a key part of Industry 4.0, a movement that’s transforming factories with powerful new technologies. All over the world, manufacturers are using robots for everything from painting and coating to inspection and more, making their factories faster, safer and more efficient. Those who use robots are getting ahead; those who don’t will soon be left behind.

But here’s the catch: Before you can use robots to their full potential, you need a factory that’s “robot-ready”. That’s where smart conveyors come in. Designed to integrate robotics into your production line, a smart conveyor can help your factory take advantage of today’s cutting-edge technologies—and be ready for tomorrow.

Here are some of the benefits you can unlock when you invest in a robot-ready smart conveyor.

Automate Tasks

At Richards-Wilcox Conveyor, we’ve seen our customers use robots for a wide range of applications: painting, coating and quality assurance, to name a few. Every day, new robots are being engineered to automate more tasks. As the technology improves, it seems there’s no limit on what can be automated.

The biggest benefit of automating these tasks is that robots can accomplish them in less time, often with greater precision and fewer errors. Automating tasks can also help with workforce issues. As employers struggle to find talent, many are turning to robots to fill gaps.

Improve Safety

One of the best ways you can ensure an employee’s safety is by removing them from a hazardous environment. Managers can use robotics to perform dangerous or physically demanding tasks, as well as to enter environments that would be high-risk for humans. With automation, humans can perform safe, less-physically demanding tasks, and leave the rest to the robots.

Adapt to Changing Production Demands

For today’s manufacturers, one of the biggest challenges is constantly shifting production demand. When demand is low, keeping a factory running at top speed means wasting time and energy. At the same time, your factory needs to be ready to quickly ramp up.

The beauty of a smart conveyor is that it’s as flexible as you need it to be. With robotics integrated at key points, your entire line is connected, allowing you to quickly ramp up or ramp down production as needed.

Be More Flexible and Responsive

Robotics can give you precise data about your cycle time, allowing you to analyze your productivity and plan your output on a daily, monthly and annual basis. Planning has always been a big part of running a factory. But now, with richer data and greater control, you can plan with more rigor—and adjust as needed.

Reduce Downtime

A smart conveyor is the ultimate tool for reducing downtime. Factory robots have numerous sensors, continuously analyzing their performance and functionality. With robots and sensors installed along your line, your smart conveyor acts as a central nervous system, sending your team signals when components need repaired, replaced or upgraded.

Unlike traditional conveyors, a smart conveyor takes a proactive approach to maintenance, so you can fix minor issues before they become major problems.

And when things do break down, robots can help. At Richards-Wilcox, we design our smart conveyors with bypass modes. When something goes wrong, you can quickly divert a carrier elsewhere while the component is being restored.

Be More Efficient and Sustainable

Robots can use materials and energy with greater precision, creating a more efficient factory and helping your business achieve its sustainability goals.

Let’s say that your factory is painting car doors. With a robotic painting system integrated into your line, you can paint with a precision that a human could not achieve. That means you can paint the same number of car doors with less paint. You can also boost your speed and productivity, allowing you to use less energy per car door. That’s good for the environment and your bottom line.

Ready to Get Started? Connect with a Conveyor Expert Today.

Adaptation has always been at the core of manufacturing. But today, there seem to be more disruptions in a week than there once were in a year, and things are only speeding up.

The best way to prepare for change is by designing for it. At Richards-Wilcox Conveyor, we design, engineer, install and maintain smart conveyors. Our conveyors are “robot-ready”, meaning that they’re designed to seamlessly integrate cutting-edge robotics systems. With Richards-Wilcox, you’re not just ready for change. You’re engineered for it.

Contact us today to see how our smart conveyor solutions can help your business.

In today’s fast-paced manufacturing world, precision and efficiency are essential. This is especially true in industries like automotive and aerospace, where tight tolerances matter.

For processes like paint finishing, even small mistakes can affect the final product’s quality. A reliable and accurate conveyor system is very important. Enter the MonoCart™ conveyor—a specialized solution for high-precision applications requiring exacting standards.

Understanding MonoCart™ Conveyors

MonoCart™ conveyors are designed for operations that demand consistent accuracy and stability. Unlike general conveyor systems, MonoCart™ conveyors work best in precise settings. They transport lightweight parts under 300 pounds with little variation.

These conveyors are designed to keep a steady position. This makes them perfect for robotic finishing systems and other automated tasks. These applications rely on precise alignment to work well.

Why Precision Matters in Paint Finishing Systems

Paint finishing systems require an unwavering level of accuracy. In the automotive industry and other sectors, even a small misalignment in the conveyor system can cause problems. This can result in uneven coating, missed sections, or paint overspray.

This is where MonoCart™ conveyors stand out. These system designs are made for precise operations, making sure each part is placed correctly. This reduces errors in robotic finishing systems.

In a typical automated paint line, robots are programmed to follow a set path and apply paint in exact patterns. If the conveyor moves even a little from its intended spot, the robotic system might paint incorrectly. This can cause defects that need expensive rework.

MonoCart™ conveyors reduce this risk by offering reliable and consistent positioning, ensuring that each product goes through the paint booth as intended.

Customization for High-Precision Applications

One of the main benefits of MonoCart™ conveyors is that they can be customized for high-precision needs. Custom conveyor design lets manufacturers create a system that meets their specific needs. This includes adjusting the speed, connecting with current automation systems, or fitting unique layout requirements.

Conveyors need to handle different part sizes and shapes. They must also keep strict quality standards. For example, a car manufacturer can use a robotic system to paint car panels. They can benefit from a MonoCart™ conveyor’s custom fixtures that hold each panel securely in place. This helps the robot apply paint evenly on all surfaces.

Applications in the Automotive Industry

The automotive industry has always led in using advanced manufacturing technologies. MonoCart™ conveyors are a great example of this. These conveyors are important for painting body panels and applying special coatings on interior parts. Automotive industry conveyors need to handle many tasks.

For jobs that require high accuracy, MonoCart™ systems are often the best choice. Their ability to handle lightweight parts with consistent precision makes them indispensable in environments where automated processes are prevalent.

MonoCart™ conveyors have a compact and modular design. This makes it easy to integrate them into existing production lines. They are a practical solution for manufacturers. These conveyors help improve automation without major changes.

Advantages of MonoCart™ Conveyors in Precision Manufacturing

• Enhanced Accuracy: MonoCart™ conveyors maintain tight tolerances that consistently position parts, reducing errors in automated processes.
• Improved Efficiency: By minimizing defects and rework, these conveyors help manufacturers increase throughput and reduce downtime.
• Customizable Design: You can tailor MonoCart™ systems to meet specific operational needs, from layout configurations to speed adjustments.
• Seamless Integration: Their modular design allows for easy incorporation into existing manufacturing lines, enhancing overall production efficiency.

Strengthen Your System With MonoCart™

MonoCart™ conveyors are a vital asset in high-precision manufacturing environments, particularly in applications like paint finishing and robotic automation. Their ability to maintain a stable position is impressive. They can handle lightweight parts easily. They also work well with advanced systems. This makes them a top choice. Manufacturers want to improve quality and efficiency, and these features help them do that.

While not a universal solution for every finishing job, MonoCart™ conveyors excel in specific applications where precision is paramount. By investing in a customized MonoCart™ system from Richards-Wilcox Conveyor, manufacturers can ensure their high-precision processes run smoothly, ultimately delivering superior products to market.

 

For today’s businesses, sustainability is a top priority. At the same time, your business can’t afford to sacrifice efficiency and productivity. So how can you implement eco-friendly practices in your conveyor system while also protecting your bottom line?

The good news is that you don’t have to choose. What’s good for the environment is often what’s good for your business. Richards-Wilcox Conveyor has partnered with clients across a wide range of industries to implement smart solutions that make businesses more sustainable and more efficient. With the right technology and strategic planning, your business can reduce your conveyor’s ecological footprint, while optimizing your resources and reducing energy consumption.

Let’s explore how technological advancements can help your business implement sustainable practices in conveyor system operations.

1. Optimized Conveyor Systems Design

Sustainability begins at the design phase.

When planning conveyor systems installation, considering energy efficiency and material usage is crucial. One of the main goals of sustainable conveyor systems design is to reduce energy consumption by ensuring that systems run only when necessary. To achieve this, you can install sensors that detect when products are present, so motors only run when needed. Meanwhile,

Variable frequency drives (VFDs) can also adjust motor speed to match the current load, further decreasing energy usage.

Designing for minimal friction and resistance within the conveyor system will reduce wear and tear, prolonging the lifespan of the components and saving you money over time. Richards-Wilcox Conveyor’s innovative designs prioritize these factors, providing businesses with a robust solution that minimizes environmental impact without sacrificing productivity.

2. Energy-Efficient Motors and Drives

One of the most effective ways to enhance conveyor sustainability is by investing in energy-efficient motors and drives.

At Richards-Wilcox, our conveyor systems can integrate with energy-saving technology that significantly reduce power consumption. Motors equipped with energy-efficient ratings and VFDs can be programmed to adjust speeds based on the conveyor’s load, reducing energy use.

For example, during periods of lighter load, the system can operate at a lower speed, saving energy. By using these technologies in your conveyor systems, your business reduces its energy footprint. Over time, this not only benefits the environment but also reduces overhead.=

3. Predictive Maintenance with IoT Integration

Predictive maintenance is a proactive approach that helps companies reduce downtime and extend the life of their equipment.

Integrating the Internet of Things (IoT) into conveyor systems takes preventative maintenance to the next level, allowing for real-time monitoring and data collection. Sensors can detect potential issues long before they lead to costly breakdowns or excessive energy usage.

By catching issues early, companies can perform maintenance as needed rather than following a rigid schedule. This reduces unnecessary parts replacements and prevents energy loss due to poorly functioning equipment.

4. Modular Conveyor Systems

For modular conveyor systems, flexibility means sustainability.

These systems are designed in sections or modules that can be easily replaced or reconfigured, without a complete system overhaul. This minimizes waste, as only the necessary parts are changed instead of replacing an entire conveyor system. Modular designs also allow businesses to scale their operations without significant investments in new infrastructure.

These systems are typically built to accommodate future technology upgrades. As new energy-saving technologies become available, businesses can integrate them into their modular systems without having to start from scratch.

5. Sustainable Conveyor Systems in Action

Richards-Wilcox has successfully implemented sustainable practices in conveyor systems across a wide range of industries. We combine eco-friendly design with modern technology. This helps companies lower their carbon footprint and improve their operations. From the initial design to ongoing maintenance and upgrades, we provide a comprehensive approach to conveyor sustainability.

The Future of Conveyors is Green.

By adopting advanced technology, such as energy-efficient motors and IoT-driven predictive maintenance, companies can achieve significant energy savings and reduce waste.

Richards-Wilcox Conveyor provides innovative solutions that help our clients achieve greater sustainability and efficiency. Whether you’re searching for a new conveyor or upgrading an existing system, implementing sustainable practices is a smart investment for both the planet and your bottom line.

Learn more about our company or shop for parts on our online store.

In manufacturing, efficient material handling is the backbone of productivity and profitability. Companies can streamline workflows, minimize waste, and maximize output by optimizing the movement, storage, and control of materials throughout production.

One innovative solution revolutionizing material handling is the heavy duty over-and-under conveyor. These advanced systems are designed to handle high volumes of materials with speed, precision, and flexibility, making them the ultimate choice for modern manufacturing environments.

Over-and-under conveyors offer a compact and efficient alternative to traditional material handling methods by transporting materials vertically and horizontally – utilizing multiple levels, optimizing space and reducing the footprint required for operations. Embracing this technology can significantly boost your manufacturing capabilities and keep you competitive in a rapidly evolving market.

What Are Over-and-Under Conveyors?

These conveyors facilitate both vertical and horizontal movement of materials, allowing for seamless transitions between different production stages.

Essential components include robust tracks, carriers that hold and transport materials, and advanced drive systems that ensure smooth operation. The Richards-Wilcox OveR-Way™ heavy duty over-and-under conveyor is particularly effective in handling large, heavy loads, making it a popular choice for industries like automotive and aerospace. These systems are part of custom material handling solutions that can be tailored to meet specific operational needs, providing flexibility and efficiency in material movement.

Advantages of Heavy Duty Over-and-Under Configurations

Heavy duty over-and-under conveyor systems offer a range of advantages that make them a standout choice for modern manufacturing.

1. Space Optimization and Increased Capacity

Over-and-under conveyors maximize vertical space utilization, allowing manufacturers to store and process materials at higher levels. This vertical movement increases overall capacity, enabling facilities to handle larger volumes without expanding their footprint.

Compared to traditional conveyors, which require extensive horizontal space, the OveR-Way™ heavy duty over and under conveyor minimizes the floor area needed for material transport. This efficiency is crucial for businesses with limited space as it allows for more effective use of their facilities.

2. Enhanced Throughput and Efficiency

These conveyor systems excel at simultaneous material handling, transporting multiple items at once. This capability significantly boosts overall throughput and ensures production lines run smoothly and efficiently.

The design of over-and-under conveyors also reduces the time it takes to move materials from point A to point B, leading to shorter cycle times. Faster material movement enhances productivity and helps manufacturers meet tight deadlines. This alone makes these systems invaluable for effective automated material handling.

3. Flexibility and Scalability

Adaptability is a key feature of over-and-under conveyors. These conveyors adapt easily to layout changes. As production needs evolve, manufacturers can reconfigure these systems without extensive downtime or costly renovations.

This adaptability allows businesses to scale operations efficiently, accommodating growth or shifts in product lines without significant infrastructure changes. Companies can respond quickly to the ebb and flow of market demands, ensuring they remain competitive.

4. Cost-Effectiveness and Improved Safety

Heavy duty over-and-under conveyors lower operational costs by reducing the need for manual handling. This automation minimizes labor expenses and decreases equipment wear and tear, leading to lower maintenance costs. The durability of these systems ensures a strong return on investment over time, as they require less frequent replacement or repair.

Additionally, these conveyors enhance workplace safety by minimizing the risks associated with manual material handling, reducing accidents and injuries. Investing in material handling and fabrication solutions like these not only streamlines operations but also creates a safer, more efficient work environment.

Key Applications of Heavy Duty Over-and-Under Conveyors

Over-and-under conveyors are essential in various manufacturing applications, providing efficient material handling solutions that enhance productivity and streamline operations.

Automotive Manufacturing

In automotive manufacturing, heavy duty over-and-under configurations are widely used to transport components between assembly stations. These conveyors facilitate the movement of heavy parts while minimizing the need for manual handling. Their design allows for efficient use of vertical space, enabling manufacturers to optimize their production lines and maintain a steady workflow.

Warehousing and Distribution

In warehousing and distribution centers, over-and-under conveyors improve the efficiency of sorting and transporting goods. They allow for simultaneous handling of multiple items, significantly increasing throughput. This capability is crucial for meeting the demands of e-commerce and rapid order fulfillment, where speed and accuracy are paramount.

Packaging Operations

Over-and-under conveyors are also utilized in packaging operations, where they transport products through various stages, including filling, sealing, and labeling. Their automated nature reduces labor costs and minimizes errors, ensuring a consistent and efficient packaging process. This aligns with the principles of automated material handling, allowing for seamless integration into existing systems.

Material Handling for Heavy Loads

These conveyors excel in environments that require the movement of heavy or bulky items, such as steel racks in manufacturing plants. They streamline material handling operations, reducing forklift and operator idle time. Investing in these systems enhances overall efficiency and productivity while optimizing material handling equipment.

Choosing the Right Heavy Duty Over-and-Under Conveyor System

Selecting the right heavy duty over-and-under conveyor system is crucial for optimizing your manufacturing operations. Here are key factors to consider.

Load Capacity

First, assess the load capacity your conveyor needs to handle. Heavy duty systems are designed for substantial weights, often exceeding 1,000 pounds per carrier. Ensure the conveyor you choose can accommodate your heaviest materials without risk of damage or failure.

System Layout

Next, consider your facility’s layout. Over-and-under conveyors excel in maximizing vertical space, making them ideal for facilities with limited floor area. Evaluate the available height and horizontal space to determine the best configuration for your operations.

Integration with Existing Systems

Companies should look for a conveyor that integrates seamlessly with their current material handling equipment. This ensures compatibility with existing systems, such as automated sorting or warehouse management software, to maintain a smooth workflow.

Customization Options

Customization options are essential for tailoring the conveyor to the company’s specific needs. Many manufacturers offer features such as adjustable speeds, specialized coatings, and varying lengths to fit unique operational requirements. This flexibility ensures that the conveyor system aligns perfectly with the production processes.

Industry 4.0 Integration

Prioritize models that offer seamless integration with Industry 4.0 technologies. Look for systems equipped with sensors and communication capabilities that enable real-time data collection, predictive maintenance, and enhanced connectivity with other manufacturing systems.

Safety Features

Finally, prioritize safety features. Choose conveyors equipped with safety interlocks and emergency stop functions. These features protect workers and minimize the risk of accidents during operation. Investing in a system that emphasizes safety not only protects the team but also the organization overall.

OveR-Way™ Heavy Duty Over and Under Conveyor

At Richards-Wilcox Conveyor, we understand the unique challenges manufacturers face in optimizing material handling. That’s why we’ve developed the OveR-Way™ Heavy Duty Over and Under Conveyor, a state-of-the-art system designed to streamline operations and boost productivity.

This innovative conveyor features a robust, heavy duty over-and-under configuration capable of handling loads up to 2,000 pounds per carrier. Its innovative design allows for both vertical and horizontal movement, maximizing space utilization and minimizing the footprint required for material transport. This efficiency is crucial for facilities with limited space, enabling them to optimize their layout and enhance workflow.

Customization is key, and we offer a range of options to tailor the OveR-Way™ conveyor to your specific needs. From adjustable speeds to specialized coatings, our team works closely with you to ensure the system aligns perfectly with your production processes.

Experience the power of the OveR-Way™ Heavy Duty Over and Under Conveyor and take your manufacturing operations to new heights. Contact us today to learn more about how this innovative solution can transform your facility.

For an unparalleled finishing conveyor, look no further than inverted conveyors from Richards-Wilcox Conveyor. While overhead conveyor systems are often the choice for finishing applications, with products hanging overhead, our variety of inverted conveyor systems and their unique benefits can make a perfect choice for a variety of paint finishing systems.

We have inverted power and free conveyor options to complement your paint equipment and finishing equipment. Our load capacities are unparalleled, and for all of our finishing line conveyors, we offer monorail, power and free conveyor solutions, automatic control, and fully installed systems for finishing conveyor applications.

But first, consider what finishing application your products require. There are two categories of finishing options: dry (powder coating) processes and wet processes (liquid paint). Each process involves a wide variety of subroutines, so consider what you need: we cater to every kind of finishing line, from washers and ovens, to spray booths and degreasers.

Your choice of coating systems can also be a deciding factor. Before the 1990s, liquid paint was the overwhelming standard: until hazardous conditions and environmental regulations paved the way for powder coating’s popularity. Powder coating works with an electrostatic dry finishing process. The parts are electrically grounded, then charged and sprayed directly with pigment and resin particles for a quality, long-lasting finish.

However, with new techniques and improved environmental impact, liquid paint has come back into popularity. Wet processes utilize electrical currents for E-coating, a technique otherwise known as electrophoretic deposition. E-coating uses an electrically charged liquid-based solution bath to deposit particles onto the product. It’s an ideal process for irregularly shaped parts with curves and crevices, like automotive bumpers or plastic components.

There are also additional methods like dip and spray systems, both of which typically use overhead conveyor systems, to evenly apply finish by dipping the product into any number of specialized solutions. On occasion, dip line finishing uses dip tanks filled with any number of different solutions, into which operators dip their products to evenly apply finish. Sometimes, tanks contain cleaning solutions or chemicals to help prepare an item for its final coating.

Wet spray appears in a large number of applications and can work on almost any product. Paint line conveyor systems apply paint or varnish to a variety of media including metals, woods and plastics. These kind of finishing applications often feature robotic components shooting industrial paint from a spray gun, paired with pressure tanks to regulate the flow of pigment.
With your method determined, it’s time to decide your means. One option is our Inverted Zig-Zag Conveyor, a monorail system with an enclosed track. The system’s innovative design uses patented Richards-Wilcox Inverted Pendants to offer unparalleled vertical flexibility. Unlike rigid pendants, Richards-Wilcox Inverted Pendants pivot forward and backward on the wheel axel, allowing free rotation of up to 30 degrees with no torque or wear on the chain. However, the cost-effective and efficient chain of our monorail conveyors may not be universally amenable to every process change you desire.

Enter our Inverted OveR-Way floor-mounted conveyor, one of our top-of-line power & free systems. On top of its clean operation and seamless robotic integration, this power & free conveyor system incorporates two rails and a trolley. This allows the system unlimited flexibility that allows stopping at key locations. For instance, with two concurrent tracks, all the painting robots in the spray booths have to do is pivot. The conveyor can then divert to multiple locations, like curing ovens.

UNPARALLELED FLEXIBILITY, RELIABILITY, AND CUSTOMIZATION

From simple paint line conveyors to large-scale robotic systems, our expert staff will engineer a custom finishing system for your operation. Do a complete 180 on your productivity with an inverted finishing line conveyor system from Richards-Wilcox Conveyor.

Richards-Wilcox Conveyor created the original enclosed track conveyor in 1938. We’ve been evolving it ever since.

Conveyors are ideal for assembly applications, and the enclosed track conveyor still proves the crown jewel of assembly line conveyor systems. Different from a belt conveyor or roller conveyors, an enclosed track conveyor boasts unique advantages: for instance, a single driving unit is capable of moving hundreds of feet of conveyor chain, meaning minimal operating cost with maximum efficiency.

We boast customizable monorail conveyor systems with system integrators in mind. Whether you need an overhead conveyor system or beam monorail conveyor, we trust the following heavy duty custom conveyor solutions will be the backbone of your factory.

Zig-Zag® Monorail

Today, this sets the industry standard for effective material handling equipment. Using standard modular components constructed for long life, Zig-Zag® Monorail conveyors solve a variety of manufacturing problems: from simple, in-line finishing to complex storage and retrieval systems. Its 75 lbs./load capacity, standard drive packages up to 750 lb. chain pull and vertical wheels on 6” centers are well complemented by the system’s versatility.

Thanks to its simplistic, modular design, Zig-Zag® Monorail tracks can be easily installed on manufacturing floors, in auto-body shops, in receiving areas, etc. Potential applications include Paint Finishing Systems, WIP Buffer Systems, Investment Casting, Progressive Assembly, Trash Conveyors, Tote Handling, Die Cast Rack Storage, Empty Carton Return, Plating Rack Storage, Sliver Can Delivery, and Robotic Interfaces.

Zig-Zag® is highly adaptable. It is the only overhead chain conveyor that can be upgraded to a power and free system utilizing all existing components. The enclosed track design shields products from contamination that typically falls from open-chain conveyors. This also protects the chain itself from airborne dirt, abrasives and solvents, prolonging the chain life.

Zig-Zag® is built with standard, modular components, making it easy to install, modify and maintain. This also guarantees quick access to parts through local stocking distributors.
At 6 inches, the Zig-Zag® chain has the shortest pitch in the industry. This allows for tighter horizontal curves and closer load pendants with less wheel loading for more product throughput. That adds up to as much as 33% more productivity.

The system’s standard 1′-6″ horizontal and 2′-0″ vertical curves can make tight changes in direction and elevation, freeing valuable floor space for other assembly and storage operations.

Zig-Zag® utilizes vertical wheels on 6″ centers, distributing the same amount of load over more wheels and reducing wear. And since the system can transport product anywhere, it minimizes product damage throughout your operation.

Safe-Rail® Monorail Enclosed Track Conveyor

Efficient and expandable, the Richards-Wilcox Safe-Rail® Monorail Conveyor is the optimal solution for hand-push transport and storage applications.

Constructed of standard Richards-Wilcox components, Safe-Rail® can be upgraded at any time to build a more sophisticated power monorail or power & free conveyor system. Conversion time is minimal and higher levels of productivity and efficiency are achieved almost immediately.

It has capacity ranging from 10 to 1,000 lbs. and utilizes 3/16″ thick straight track (the heaviest in the industry). We stock it in 10′ lengths, it can do horizontal curves, (3/16″ thick, 90°). Safe-Rail® has Frog Switches, VMTs to automatically raise or lower product, a Carrier Insert Section, Welding Jigs, and Carrier Assemblies.

This is a consummate assembly rig, perfect for Batch Paint Systems, Tire Retread Systems, Tool Support Systems, Synthetic Fiber Handling, Light-Duty Bridge Cranes, and Manual Transport and Assembly.

This solution is highly adaptable. Safe-Rail® can be upgraded to a Zig-Zag® or Twin-Trak® system with 100 percent utilization of existing parts.

Safe-Rail® is a hand-push transport and storage alternative to manual re-handling of product. This decreases the potential for loss or damage.

Safe-Rail® frees up vital floor space, providing product movement throughout a facility and allowing for organized product flow.

It makes the most of the space you have. Safe-Rail® provides dedicated storage in user-specified areas. This system eliminates wasted space and efficiently stores product in an organized manner within the same work areas, day after day.

It protects your product and keeps your workers safe. Since product is suspended from a Safe-Rail® carrier, manual re-handling of product is kept to a minimum, reducing the chance of product damage. VMTs automatically raise and lower product, eliminating injuries related to lifting and bending.

And it’s built to last. The enclosed track design protects carriers and runways from dirt and other contaminants. In addition, Safe-Rail®’s sliding frog plates support loads through switches providing both smooth travel and longer switch life.

Richards-Wilcox Conveyor can custom design any of the above systems, and beyond. The future is here: we’ll evolve your factory to match.

Conveyor controls are critical to the efficiency and optimization of your entire conveyor.

Think of your conveyor system as a body. You have good bones, but you need a smart brain. That’s why you need a strong conveyor control. When you enable system integration with your host computer (or other software systems) you have an optimized, holistic system that’s engineered to evolve alongside you. Below we talk about some of the benefits of a control system for your conveyor.

The right conveying controls saves time, money and efficiency. It will optimize your material handling systems and warehouse operations. It will allow for variable production rates and quick production changes. Programmable Logic Controls (PLC) allow for this necessary direct system control. This centralized network-oriented approach is best primed for automation and attaining the numbers you need to thrive.

You also need a system with intuitive operator interfaces that collects, views, stores, controls, analyzes, and manages conveyor information from the facility floor in real-time. This makes it easy for a project manager to interpret and implement changes or repairs on your productions lines. When operators and maintenance workers don’t have to take as much time troubleshooting, when they have a smart conveyor control that helps process, diagnose and debug issues quickly, it ensures your potential downtime is not your downfall.

The right conveyor control allows for built-in adaptation. Your controls should be expandable and flexible to improve workflow and meet new requirements and accommodate for additions and adaptations as you grow and generate more order fulfillment.

A smart system control software even saves lives. A conveyor control should have smart motor controllers to stop your conveyor belt in the event of emergency. It should automatically shut down the system in the case of malfunction, because any breach of protocol could not only harm your bottom line – it could potentially harm any worker on the line.

At Richards-Wilcox Conveyor, we specialize in conveyor systems design. We’ve designed conveyor systems for every size and scope of facility. We understand your factory, learn its unique needs, and know what it needs to be future-ready. We optimize your level controller, belt tension, motion control, flat belt, and material handling equipment. 

It’s essential to make your conveyor design optimized to your own space. It’s why our applications include the execution of conveyor simulations – computer-generated models to check how a conveyor system will work, before it’s ever built. The right conveyor control can even create these kinds of simulations to help evaluate new ideas for optimization.

We understand your factory, learn its unique needs, and know what it needs for the future. But whether we’re exploring a new system designed from scratch or testing out proposed modifications to an existing system, the right conveyor control makes it all click. That’s what really makes you engineered for evolution.