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Streamlining Pallet Handling: A Chain Conveyor System Design

Streamlining Pallet Handling: A Chain Conveyor System Design

Feb 5, 2025

Case Studies

Streamlining Pallet Handling: A Chain Conveyor System Design

Efficient pallet handling is crucial for any warehouse or manufacturing operation. Recently, we tackled a project requiring a robust and precise system to move heavy pallets loaded with paper through a loading and packaging process.

The challenge: heavy pallets, precise movement

Our customer needed a conveyor system capable of handling substantial pallet weights while concurrently maintaining accurate positioning for subsequent operations. The key requirements were:

  • Pallet Dimensions: 1200 x 800mm
  • Throughput/Speed: 12 meters per minute
  • Pallet Weight: 1000 kg
  • Orientation: Wide edge leading
  • Integration: Seamless transfer to a customer-supplied pallet loading station with a servo drive (a sophisticated electronic motor that controls a very precise movement), followed by a two-way strapping and wrapping station.
  • Discharge: Presentation of finished pallets for forklift truck (FLT) offloading.

These specifications presented a number of challenges. The heavy pallet weight demanded a robust conveyor design. Furthermore, the required speed and precise transfer to the loading station meant accurate control and smooth movement. Finally, integration with the customer’s existing servo drive and subsequent packaging equipment was essential.

The solution: robust design and complete control

Our proposed solution was a combination of proven technology and careful design:

  • Low Profile Triple Chain Conveyors: We specified heavy-duty, low-profile triple chain conveyors using 5/8 pitch chains. This design gives the strength and durability to handle 1000kg pallets while the low profile simultaneously makes for easy loading and unloading. The triple chain configuration ensures even weight distribution and smooth pallet movement.
  • Compact 180-Degree Rotation Turntable: A compact, 180-degree rotation turntable was incorporated to precisely orient the pallets. In addition, the turntable features an externally mounted gearbox and motor for easy maintenance and accessibility.
  • Braked Motors: Braked motors were included to ensure precise stopping and positioning of the pallets.
  • Customer Servo Drive Integration: Seamless integration with the customer’s existing servo drive was a key element of the solution. For the most part, this was to allow precise control in placing the pallets where they were needed in the operation.
  • Conveyor Bridging Transfers: To facilitate smooth and seamless pallet transfers at conveyor intersections we introduced conveyor bridging transfers to add additional support and regulation.

The turntable section design

Paper handling new invention

The outcome

This comprehensive solution addresses all of the customer’s requirements to provide a significantly robust, efficient, and accurate pallet handling system. The combination of heavy-duty components, precise control mechanisms and seamless integration undeniably ensures a smooth operation and optimal throughput.

In summary, we have delivered a great solution that has been a game changer for this customer’s pallet handling by carefully considering their needs and applying our expertise in conveyor system design.

The design becomes a reality

Paper handling new invention

Need help with pallet handling?

We have the brains and the muscle to get you the perfect tailored solution that can handle even the heaviest pallet. Call us on 01623 354473 or see the other ways you can get in touch.

PJP and the Chocolate Factory – A Pallet Conveyor System

PJP and the Chocolate Factory – A Pallet Conveyor System

Aug 6, 2024

Case Studies

PJP and the Chocolate Factory – A Pallet Conveyor System

A pallet conveyor system has a mighty challenge

Pallets are essential for streamlining production flow and managing storage capacities, however, they can weigh an absolute tonne! Incredibly robust roller conveyors and fully bi-directional pallet lifts feature on this PJP pallet conveyor system which certainly offers flexibility and strength to transfer pallets.

A heavyweight system with tasty outputs

This system can easily handle a heavyweight pallet challenge. It transports, lifts and lowers multiple sized pallets weighing up to 1500Kg. The items that sit on the pallets vary a lot. One might contain tubs of powder, packaging materials, factory waste or finished goods, which in this case is delicious chocolate confectionary.

Horizontal and vertical journeys

Delivery waggons bring in the pallets. Special forklift load centre points ensure a safe transfer from trucks to a large transport conveyor.

Multiple locations then beckon. Pallets could travel along one level to go into bulk storage. Alternatively, they may need to be diverted to one of many operational locations on the first floor. Bespoke pallet lifts, specially designed and installed by PJP, transport the items up and down if this is the case.

No danger of hitching a ride on these lifts

Pallets feed in and out of the lifts in single file via dedicated pallet conveyor lanes. These conveyors include light guards at all entry and exit points to safely prevent operator access. This means only pallets can enter the system. If any other transport medium (or person) attempts to gain entry into a lift, the system instantly stops and requires manual resetting.

Safety is always important in material handling applications, but its importance is paramount when lifting and lowering heavy loads!

Exceptional results

This system is now used 24 hours per day, 5 days per week and has completely transformed operations on site. We have certainly created remarkable productivity increases in many processes with this system.

Want to see how we can help you?

This is just one examples of PJP’s successful projects. We deliver success for our customers and we’re proud of that. Contact us to see how we could help you achieve your ambitions.

Pallet conveyor system - pallet lift
Pallet conveyor system lift at its top level

Leading Cosmetics Manufacturer Benefits from PJP Pre-Planned Maintenance

Leading Cosmetics Manufacturer Benefits from PJP Pre-Planned Maintenance

May 14, 2024

Case Studies

Leading Cosmetics Manufacturer Benefits from PJP Pre-Planned Maintenance

One savvy cosmetics manufacturer has turned to PJP to proactively address potential issues in their conveyor operations before they escalate into more significant problems. As a manufacturing business, they need to be able to trust their machines and technology to run operations smoothly. An unexpected breakdown or equipment failure could spell disaster in terms of costly downtime, reduced productivity, eroded profits and unhappy customers. That’s why conveyor maintenance and support is key.

Conveyor maintenance checklists are crucial

PJP takes a planned and systematic approach to maintaining the customer’s machinery, equipment and systems. This involves regularly servicing and inspecting the customer’s operational assets. At our most recent visit, we meticulously went through a huge checklist of items.

We checked everything to do with their conveyor’s rollers, bands, shafts, chains, joints, gates, fan vents, sensors, pull cords, motors… then cleaned, fixed, re-positioned and re-tensioned as needed.

 

Safety is paramount in the operation

Our visits are also the perfect opportunity to assess the safety of the entire operation. This is a hugely important aspect of our conveyor maintenance regimes. Safety checks and inspections help identify potential hazards or faulty components that could pose a threat to employees’ well-being. By addressing these issues promptly, the customer creates a safer working environment, reducing the chances of accidents or injuries.

Reduce, reuse & recycle

When installing spares, in line with the customer’s wishes, we use reconditioned parts when possible. This had sustainability benefits and keeps down the cost of the service.

We now have a watch list for the parts of their conveyors that are likely to need attention when we next come over. Everything is done in collaboration with the customer so there are no sharp intakes of breath. Just a reliable and fully working conveyor system that will have a significantly longer lifespan due to the care that we are taking over it.

 

Looking after other manufacturers’ conveyors too

Did you know that we look after many conveyors that have been supplied by other manufacturers – not just the ones that we make?

To find out about our affordable servicing and maintenance packages for manufacturing, warehousing and distribution conveyors, get in touch for a no obligation quote.

Conveyor maintenance | Inspecting, cleaning & fixing elements
Conveyor Maintenence | Looking at systems from every angle
Conveyor Maintenance | Roller conveyor
Conveyor Maintenance | Electrical control conveyor system
Multi-faceted conveyor with rollers, belt & transfer unit

Conveyor Move and Upgrade for International Security Product Supplier

Conveyor Move and Upgrade for International Security Product Supplier

Feb 1, 2024

Case Studies

Conveyor Move and Upgrade for International Security Product Supplier

Industrial conveyors, like this one, sometimes need a bit of a facelift to support new processes. Working with what you already have and replacing sections can be a super efficient way to create a solution.

The requirement

PJP were asked to change the layout of a conveyor system by a longstanding customer in the security product sector. The customer also wanted to upgrade various sections. The aim for both of these requests was to fully support new processes.

A strategy that meant no downtime

PJP carried out the work over two weekends. This meant no downtime or hassle for the customer during their working hours.

Following 50% completion over the first weekend we left the conveyor in a working state in its new position. We had included a temporary outfeed to ensure the customer could continue as normal with picking, scanning and despatch. The project was complete by the end of the following weekend.

What we delivered

We removed the old and problematic transfers and replaced them with modern F-RAT units by Itoh Denki. These transfer units can reliably transfers items at horizontal 90 degree angles. 24v zero line pressure (ZLP) conveyors replaced an outdated belt driven roller section. Scanner outputs were changed to sortation lanes which suited new carrier label processes.

A newer version of programmable logic controller (PLC) software came next. We future-proofed the software to support operations both now and in the forthcoming years. We also adapted the human-machine interface (HMI) to the new layout and added in useful new HMI functionality.

Finally, we tested and commissioned the whole system with the client. This ensured it performed exactly as required.

Job done.

F-Rat Transfer Unit on Industrial Conveyor
Sortation Lane on Roller Conveyor Section
Curved Roller Conveyor Section
Camera Scanners on Industrial Conveyor System

Do your industrial conveyors need improving?

This is just one example of how we work with clients to enhance their conveyor processes to modernise them. PJP Conveyors pride themselves on listening to customers to fully understand their requirements before coming up with solutions that suit their needs and budget.

Contact us for expert guidance on improving your conveyors.

Twin Conveyor Belt System for Printing on Containers

Twin Conveyor Belt System for Printing on Containers

Jan 11, 2024

Case Studies

Twin Conveyor Belt System for Printing on Containers

We can engineer a conveyor belt system in all sorts of clever ways to allow for special operational procedures. 

Helping the food industry print on packaging

Have you ever noticed that food packaging often has information printed directly onto it, in addition to its label? Usually this is ‘Best Before’ or ‘Use By’ information.

To print like this, you need something like one of these PJP twin belt conveyors. It has a central gap to allow for ink jet printing on the base of containers.

The gap is large enough for a print head but small enough that products won’t fall through it. Products sit solidly on both belts bridging the gap.

Strict hygiene requirements accompany anything to do with food. This system has been built for a fish-processor, hence, it is manufactured from Stainless Steel. The plastic modular belt design we’ve chosen is suitable for washing down and easy cleaning.

An adaptable and safe solution

Flexibility is built into the design. It has adjustable side guides. We’ve also introduced lockable castors so the whole unit is easy to move around.

We maintain Safecontractor accreditation and its priciples feed through into everything we do. Health and safety is paramount in all our designs. So naturally, there won’t be any concerns like finger traps.

This particular conveyor is now used over in Ireland, supporting the food industry.

Could a conveyor belt system help your operations?

Please Contact us to find out more about the different conveyor belt systems we offer. These suit a multitude of manufacturing, processing, retail  and warehouse requirements. We will use our extensive engineering and design skills to find the best standard or bespoke solution for your needs.

Twin belt conveyor in a fish processing application
Twin Conveyor Belt System with a gap for printing on containers