Integrating Smart Conveyor Technologies into Production

Conveyor technologies have moved a long way from simple belt loops. Today’s systems cut labour costs, lift throughput, and allow factories to run around the clock without compromising quality. Recent studies show that advanced conveyor belts can boost production speed by up to 30 per cent compared with legacy setups. They also slot neatly into Industry 4.0 environments, sharing data with sensors, robots, and warehouse software so that decisions happen in real time.

Cutting Labour Costs and Boosting Throughput

Automated conveying removes manual carrying, so teams can focus on tasks that add real value – quality checks, process control, and innovation. By reducing repetitive lifting and walking, businesses save on both wages and injury claims.

Supporting smart factories

Modern conveyor technologies come with plug-and-play tracking, barcode readers, and edge computing. These features feed performance data straight into your MES or ERP, letting managers spot slowdowns before they hit the schedule.

Types of conveyor technologies and where they fit

Before ordering hardware, match the conveyor style to the product, speed, and hygiene level required.

Belt conveyors – the all-rounder

Standard belt systems move everything from parcels to packaged food. They remain the most cost-effective choice for straight-line transport at moderate speeds.

Modular conveyors for flexible layouts

Modular conveyors arrive in pre-engineered sections that you can bolt together, move, or extend within hours. They’re ideal for e-commerce fulfilment and seasonal production changes because you can re-route lines with minimal downtime.

Cleanroom and hygienic conveyors

Medical devices, electronics, and food all need ultra-clean handling. Look for stainless-steel or FDA-approved plastic flights plus easy-wash frames. Belt edges should be sealed to avoid debris build-up.

Planning a Conveyor Integration Project

A well-planned layout pays for itself quickly. Skipping the basics often means expensive rework later.

Mapping product flow

Start with a value-stream map of your current process. Note bottlenecks, manual transfer points, and areas where stock piles up. Then sketch the ideal future flow and pinpoint where conveyor technologies will save the most time.

Designing with modular aluminium frames

Using aluminium profile systems speeds up both design and build. Components are lightweight yet strong, and the connector slots make adjustments painless. Kanya’s own extrusion system, for example, underpins bespoke conveyor lines across many sectors.

Common challenges and how to overcome them

Even the best kit fails if installed without regard for real-world constraints.

Space constraints

Older plants rarely have perfectly straight aisles. Fortunately, low-profile drives, curved modules, and vertical lifts let you thread conveyors through tight spaces without drilling new openings.

Safety and standards compliance

UK factories must align with PUWER, CE marking, and ISO 13849 on machine safety. Build in guards, light curtains, and emergency stops from day one. Modular aluminium frames make it simpler to add compliant guarding without custom welding.

Measuring the ROI of conveyor technologies

Key performance metrics

– Throughput: units per hour before and after installation
– Labour hours saved: operator time re-assigned to higher-value work
– Scrap rate: reduced damage through gentler material handling
– Downtime: minutes lost to jams or changeovers

Track these KPIs for three months, then compare them with your baseline figures to show clear payback.

Future trends to watch

Smart belts and AI-driven maintenance

Machine-learning tools now predict wear by listening to motor noise or reading vibration signatures. Smart belts also include embedded RFID chips so that spares ordering is automatic, keeping unplanned stoppages to a minimum.

How Kanya UK can help

Need an agile conveyor system built to your exact brief? Kanya UK’s award-winning design team use the original Kanya aluminium profile connect technology to deliver bespoke conveyors, pre-assembled in our Hampshire factory, FAT-tested, and installed by qualified engineers. Talk to our experts today and discover how easily you can streamline your production line.

Frequently asked questions about conveyor technologies

How long does it take to install a new conveyor line?

A modular system can be up and running in days rather than weeks, depending on site readiness.

Do conveyors replace staff?

They shift workers away from manual handling towards quality, programming, and supervision, improving job satisfaction.

Can I integrate conveyors with my existing robots?

Yes. Most PLCs support common field-bus or Ethernet protocols, letting conveyors share data with cobots and pick-and-place arms.