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Beyond the Belt: Why Conveyors Are Secretly Awesome (and Full of Fun!)

Beyond the Belt: Why Conveyors Are Secretly Awesome (and Full of Fun!)

Jan 29, 2026

Pipistrelle bat leaning over the top of a fence
Beyond the Belt: Why Conveyors Are Secretly Awesome (and Full of Fun!)

When you hear the word “conveyor,” what comes to mind? Probably a luggage carousel, a supermarket checkout or maybe a factory assembly line. These are important uses but they don’t portray the fun world of conveyors very well!

Conveyors are, at their heart, incredibly versatile systems for moving things from one place to another. But it’s this fundamental simplicity that opens up a universe of creative possibilities.

Let’s dive into some examples that will make you rethink everything you thought you knew about these humble machines.

The Bat Accelerator

Bats are synonymous with their calls and echoes. Scientists have reimagined a conveyor system to research how bats compute the echoes they make when they fly.

When flying, a bat’s echoes return at different rates depending on how near they are to objects are and how fast they are flying. This creates a kind of ‘sound flow’ but the detail on how this is used by the bat has always been a bit of mystery.

A conveyor system was created to learn more. It had 8,000 revolving panels clad in plastic ivy on either side of an eight-meter stretch of woodland path: a well-known commuting corridor for wild pipistrelle bats in Bristol. The panels rotated either in the same or opposite direction of bat flight.

This system revealed that when panels rotated in the direction of flight, bats flew faster. When panels rotated in the opposite direction, bats slowed down—by as much as 28 percent. So, conveyors can officially speed up and slow down bats. More findings on this University of Bristol study are here.

A screen grab from the influencer Joeseph's Machines video showing a conveyor belt with objects on including salad leaves which are being blown into a man's mouth by a hairdryer.

The Conveyor-5-Course-Meal-Feeder

If you’ve ever watched a “Joseph’s Machine” video, you know the pure delight of watching everyday objects perform intricate, Wallace & Gromit style sequences. And guess what can play a starring role in these elaborate contraptions? You’ve guessed it – conveyors!

When this team re-purposed an IKEA roller blind into a belt conveyor that ingeniously feeds you a 5 course meal courtesy of everyday objects… you have to see it. 15 million other people already have.

Theme Park Thrills

Ever ridden a log flume or a roller coaster?

Chances are, conveyors are working behind the scenes, pulling your boat up a steep incline or guiding your vehicle through an immersive experience.

They’re essential for creating those seamless transitions and exciting drops that make theme park rides so memorable.

Roller Coaster
Theatres scene showing three sillhouettes behind the red curtain in different poses

Musical Theatrics

Special effects are expected in most big theatre shows these days and conveyors can very much be a part of these jaw-dropping effects. In the West End and other theatrical homes, conveyors are often used as travellators for dancers and actors to make fluid movements without toing and froing from stage left to stage right. A crucial requirement  of these conveyors is quietness as noisy machinery really does spoil a good musical!

Looking Beyond The Obvious

The next time you encounter a conveyor, consider its ingenious engineering and the potential for unexpected applications. A lot of fun can be had when you combine creativity and conveyors. From accelerating bats to creating theatrical spectacles, conveyors are far more exciting than they often get credit for.

 

Are you a theatre company employee, a theme park manager, an influencer or a bat scientist? If so, we are here for all your conveyor needs – get in touch on 01623 354473.

Pallets are Becoming More Reusable and we LOVE it

Pallets are Becoming More Reusable and we LOVE it

Nov 13, 2025

Pallet handling is in our blood and we’ve noticed an interesting shift…

Lockdown made pallet waste visible

How many vertical planters were made out of wooden pallets in lockdown? That strange era introduced many UK consumers to the prevalence of single use pallets as we merrily shopped online for garden furniture, desks, freezers, gym equipment, hot tubs… to try and turn our temporary prisons into homes that we could enjoy, or at least endure.

A new era in reusable pallet models

We’re pleased to report a noticeable shift in the pallet world. Pallets are becoming reusable and repairable with pallet suppliers such as CHEP and PECO Pallet leading the way here. These organisations, and others with a similar ethos, are creating sharing pallet models that keep pallets out of landfill (and gardens).

Along with enormous environmental benefits, there are also economical benefits since the need for buying pallet stock disappears. This can be brilliant for anyone only wishing to use pallets temporarily such as for events.

How it works

It’s a simple idea that is really catching on:

  1. Customers rent out high quality pallets to transport their materials
  2. Pallets are periodically returned to depots
  3. Each pallet is rigorously inspected and, if necessary, repaired to ensure it is safe to use
  4. Out they go to a customer again

How many times can you reuse a pallet?

So how reusable is a pallet? For wooden pallets you can expect 5-10 years of use if each one transports items 30 times per year. So that equates to up to 300 uses per pallet.

In fact, our conveyors have been known to carry pallets made of plastic and even metal – all with different levels of durability and reusability.

Long live pallets!

Need any pallet handling?

We have an abundance of warehouse-focused customers so naturally pallets are a common cargo for our conveyors. We’d be delighted to help you get your pallets from A to B. Simply contact us.

Unlocking Efficiency: A Guide To Roller Conveyors

Unlocking Efficiency: A Guide To Roller Conveyors

Apr 10, 2025

Unlocking Efficiency: A Guide To Roller Conveyors

In the fast-paced world of logistics, manufacturing and retail, efficiency is king. One essential tool that streamlines material handling is the roller conveyor. Whether you’re moving packages or industrial components, a well-designed roller conveyor system boosts productivity and reduces operational costs.

Let’s delve into the ins and outs of roller conveyors, explicitly exploring their types, applications, and benefits.

What is a Roller Conveyor?

A roller conveyor is a material handling system that uses a series of rollers to transport items along a horizontal or inclined plane. Rollers are mounted in a frame which creates the potential for smooth and efficient movement. Consequently, friction is minimised, as is the need for manual intervention.

Types of Roller Conveyors: Tailored to Your Needs

The versatility of roller conveyors lies in their adaptability to various applications. Here’s a breakdown of the common types:

Gravity Roller Conveyors:

    • These rely on gravity to move items down an incline (but best avoided for fragile items).
    • Ideal for simple, non-powered applications.
    • Cost-effective, easy to maintain and also great for the planet.

Powered Roller Conveyors:

    • Use motors and chains, shafts or belts to drive rollers in a controlled movement.
    • Suitable for heavier items and complex systems such as those involving longer distances or bends.
    • Offer precise speed control and can be bi-directional.

Zero Line Pressure Roller Conveyors:

    • A type of powered conveyor with zones that are each powered individually.
    • Sensors along the line detect items and tell the system to turn on or off a zone’s rollers to ensure space is maintained and no pressure builds up.
    • Minimises product damage, power usage and health and safety issues whilst optimising flow.

Heavy-Duty Roller Conveyors:

    • Designed to handle substantial loads and harsh environments such as those in some chemical industries.
    • Constructed with robust materials for durability and longevity.

Applications Across Industries

Roller conveyors are used in a wide range of industries, including:

Warehousing and Distribution for simultaneously streamlining both order fulfilment and package handling.

Manufacturing where they undeniably facilitate assembly lines along with material movement between workstations.

Automotive for transporting parts and components through production processes.

Food and Beverage handling to ensure crates, boxes and pallets are handled as quickly and efficiently as possible.

Benefits of Implementing Roller Conveyors

Investing in a roller conveyor system offers many advantages:

1) Increased Efficiency: The automation they provide reduces manual labour and speeds up material flow.

2) Improved Productivity: Consistent and reliable transport minimises costly downtime.

3) Enhanced Safety: Reduces the risk of injuries associated with manual lifting and handling.

4) Cost Reduction: Lowers manual labour costs and optimises operational efficiency.

5) Flexibility and Scalability: Easily adaptable to changing needs and expanding operations.

Real-World Application: PJP Conveyors’ Custom Roller Conveyor Solution

To illustrate the power of tailored roller conveyor systems, consider a recent project by PJP Conveyors. We designed and manufactured a complex chain-driven powered roller conveyor system for a major UK integrator. It needed to transport heavy castings through various machining processes.

We powered the rollers with a chain due to the weight of the items being transported and the required traction.

 

Key features of this custom system

  • Transporting castings on common steel pallets with specialised fixture mountings and location pockets for precise robot interface alignment.
  • Integration of damper stops, pallet clamps, twin belt lift and transfer units for controlled and accurate material handling.
  • A robust design featuring 50mm diameter BZP rollers with twin 14-tooth x ½” sprockets. All interconnected via daisy chain drives and spaced at a 126mm pitch.
  • A durable drive system mounted in a mild steel laser-folded profile with a powder-coated finish.
plastic modular conveyor belt

This project highlights PJP Conveyors’ collaborative approach, working closely with the client to deliver a complete, functional solution. It also showcases the ability of roller conveyors to integrate seamlessly into complex automated workflows.

Choosing the Right Roller Conveyor

Selecting the appropriate roller conveyor requires careful consideration several factors. These include:

  • Load capacity and size of materials.
  • Required speed and throughput.
  • Environmental conditions.
  • System layout and integration needs.

Conclusion

Roller conveyors are indispensable tools for businesses seeking to optimise their material handling processes. By understanding what the different types of roller conveyors offer, you can leverage the benefits that are important to you – be that efficiency, cost reduction,  productivity increases – or all three!

Whether you need a simple gravity system or a complex powered solution, we’ve shown that the right roller conveyor can transform your operations.

If you are looking to upgrade your material handling systems, consider the advantages of a well planned out roller conveyor system.

For further help on choosing the right option for you, why not get in touch?

The Conveyor Belt – Here’s Everything You Need to Know

The Conveyor Belt – Here’s Everything You Need to Know

Jan 28, 2025

The Conveyor Belt – Here’s Everything You Need to Know

You most likely know what a conveyor belt is. Some people call them belt conveyors and we also encounter our customers calling them various pet names like ‘the belt’ or ‘the mover thingy’. It all really means the same thing (even though technically a ‘conveyor belt’ is only belt part of the ‘belt conveyor’… but for the sake of this article it’s all one and the same thing.)

What is a Conveyor Belt?

Conveyor belts are a moving band that transports items from one place to another. Think of a supermarket checkout moving your groceries towards the cashier, or plates of sushi snaking their way around a Japanese restaurant on a tabletop conveyor belt.

These two examples are illustrative of fairly small conveyor belts. There are actually lots of different sized options with a wide range of uses from small indoor projects to colossal applications. You might find the largest belts used in recycling plants, construction projects or as part of huge systems spanning entire warehouses.

How do they work?

Conveyor Belts typically consist of:

  1. A belt: This is the continuous band that moves the materials. It can be made from various materials, such as rubber, plastic, or metal, depending on the application.
  2. A drive roller & tail roller: A motor powers the drive roller which drives the belt round. The tail roller is a non-powered roller at the other end of the belt.
  3. A frame: A structure to hold everything in place. It also gives a base for the belt to run on.

How long has the conveyor belt been around for?

Here’s a very condensed timeline.

  • Early 1800s: The first conveyors emerged as hand-operated contraptions used to move cargo items on and off ships in port.
  • 1892: Steam powered conveyor belt systems started being used in mining.
  • 1913: Henry Ford introduced conveyor belts into his Model T assembly line.
  • Now: Since then, conveyor belts have become a lot quieter. Most are now electric and you’ll also find solar powered ones. They are constantly evolving into ever more efficient and high-tech creations that can even self-clean themselves. They often form part of smart systems using sensors and analytics for super slick materials handling. You’ll also find them working in conjunction with robots and automated guided vehicles (AGVs).

 

Types of different belts

What the actual belt is made of can change a conveyor belt’s function significantly. Here are the most common belts that we encounter.

Plastic Modular belts

This type of conveyor is very versatile. It can transport items horizontally, around corners and even up and down inclines. Plastic modular belt conveyors are very easy to wash down. This makes them ideal for food processing or for any industrial or pharmaceutical processes where strict hygiene is important.

plastic modular conveyor belt
PVC conveyor belt

 

PVC belts

PVC conveyor belts have a flexible structure and are used for light to medium-duty applications in dry environments. They are perfect for transporting boxes, textiles, and non-abrasive materials.

Polyurethane (PU) belts

PU conveyor belts are durable and used for demanding applications in a variety of industries. They can handle heavy loads, abrasive materials like chemicals, extreme temperatures, humidity, oil and hygiene-critical settings. The mining, pharmaceutical and food processing industries often use this type of belt.

Polyurethane (PU) conveyor belt
Heavy Duty Rubber Conveyor belt

Heavy Duty Rubber belts

These move heavy, sharp or rough materials that could damage other types of belts. They are resilient to constant friction and movement so you’ll find them used in industries like mining, construction and manufacturing.

The key benefits of conveyor belts

Whilst the mechanism of a conveyor belt seems like a simple machine, they play a vital role in the modern world. They efficiently and reliably move materials which increases productivity, reduces costs and improves safety across a wide range of industries.

Many conveyor belts are permanently situated. However, an increasing number have flexibility built in so that sections can be added or moved. This means you can change their usage and also make the best use of space or restricted areas – you’ll just need a little clever design know-how from someone like PJP Conveyors.

 

Thank you for reading our blog all about conveyor belts, we hope you have a better understanding of them. As a friendly conveyor manufacturer with a wealth of conveyor system knowledge, please get in touch on 01623 354473 if you have any questions.

Spiral Gravity Chutes look like Helter Skelters!

Spiral Gravity Chutes look like Helter Skelters!

Oct 23, 2024

Spiral Gravity Chutes

Spiral gravity chutes look really cool. They are the helter skelters of factories and warehouses. It’s important to note that they are not employee playground toys though, we certainly wouldn’t recommend that!

 

From high to low

You’ll typically find spiral gravity chutes quickly transferring boxed items or tote bins from a high level area – like a mezzanine floor – to the ground floor.

 

Great for when space is at a premium

Their spiral shape makes the best use of space in confined areas when conventional decline belt conveyors simply wouldn’t be able to achieve an appropriate angle. The spiralled design and chute camber enable products to descend in a very controlled manner. Brake rollers often slow the product down at the exit point.

And spiral gravity chutes are easy to assemble on site. Reinforced fibreglass moulding segments bolt together are fitted around a central supporting post.

 

Multiple configurations possible to support your needs

You can have spiral gravity chutes just the way you like them. Numerous infeed and outfeed configurations are possible and multiple layout options are available by using entry and exit extension modules.

Our spiral chutes can handle loads of up to 25kgs. We always test to make sure they can support the items that you need handling.

The pictures shown are spiral chute applications that handle shoes and trainers. Also shown is one for automative small parts picking.

 

Fancy your own chute?

If you think your operations would benefit from a spiral gravity chute, don’t hesitate to contact us. You’ll be in safe hands. These chutes are just one type of spiral conveyor that we offer. Different scenarios call for different solutions and we would be delighted to help you find the right one for your factory or warehouse.

Spiral gravity chute from ground level
Spiral gravity chute from elevated level