How To Improve The Efficiency Of Warehouse Conveyor Systems

Warehouse conveyor systems are indispensable for a manufacturer. They aid in transporting products throughout the facility for various processes like packing, loading, unloading, etc. They are ideal for warehouses that deal in large production.

These conveyor systems assist the warehouse owners in handling a high volume of SKUs. These systems facilitate easy shifting of the goods between zones without having to pick and drop them manually.

Warehouse conveyor systems can handle heavy loads, thus they simplify the entire operation. There are many benefits associated with warehouse conveyor systems like faster turnaround times, and cost-efficient and smoother operation.

However, there can always be room for better, right? In this blog, we highlight seven ways you can increase the efficiency of these conveyor systems.

How To Improve The Efficiency Of Warehouse Conveyor Systems

Ways To Improve The Efficiency Of Warehouse Conveyor Systems

1. Optimizing conveyor system

Optimizing your conveyor system is one of the easiest and most effective methods when it comes to increasing efficiency. However, there are several factors to consider. Ensuring the layout of the conveyor system for maximum efficiency is the first and foremost step.

You must also analyze the flow of goods within the facility and tweak your system accordingly. This will make sure there are no unnecessary detours. You can also consider automation wherever possible. This can be done by installing position sensors at the right locations to help the conveyor system detect what is coming.

Another way you can optimize the conveyor system is by training your staff appropriately. Even though conveyor belts are machine-operated, having no human touch is practically impossible. Trained staff can improve the efficiency by miles. 

2. Choosing the right conveyor system

Choosing the right conveyor system for your warehouse is crucial for improving efficiency and productivity. Even though this sounds very easy and doable, many fail to address this parameter.

You must get down to the specifics of your warehouse’s operations and assess them. This includes considering the type, size, weight, and dimensions of your products. This will help you get a clear idea about the type of conveyor system you need.

You might need either a chain conveyor or a belt conveyor. You must also not forget to evaluate the space of your facility. If you face limited floor space then a vertical conveyor system might be just the right one for you.

Apart from these, you can also consider the speed of the belt that suits your requirements, the flexibility and the growth aspect of your business, etc. By carefully assessing these factors, you can opt for the right conveyor system for your warehouse that will not only function efficiently but also last longer.

3. Selecting the right material

The type of material you choose can impact the speed, durability, and overall performance of your conveyor system. Hence, this point can never be overlooked. To identify the right material for your conveyor system, it is important that you consider the weight and size of the items being transported on the conveyor.

Heavy or oversized items may require a more robust material such as steel or reinforced rubber belts to ensure they can withstand the load. Another factor to be considered is the environment in which your conveyor system will be operating.

If it will be exposed to moisture or harsh chemicals, choosing a corrosion-resistant material like stainless steel or plastic can help prolong its lifespan and prevent damage. Next up is evaluating the friction between the material and conveyed products.

Low-friction materials like polyurethane or nylon can reduce energy consumption by minimizing resistance while maintaining smooth movement along the conveyor.

4. Swap in a premium-efficiency motor

The type of motor you use can make all the difference when it comes to improving the efficiency of warehouse conveyor systems. Swapping your current motor to a premium-efficiency motor can have a significant impact on energy consumption and overall system performance.

These motors are designed to operate at higher levels of efficiency compared to their standard counterparts. They are built with advanced technologies that reduce energy losses and improve power output. This switch to a premium-efficiency motor will also reduce electricity bills and lower maintenance costs.

Additional features like variable speed control and durability will make sure your warehouse conveyor system functions efficiently for a longer period. In short, swapping your current motor for a premium-efficiency motor is one of the best investments that you can make for your warehouse.

5. Replace old conveyor systems at regular intervals

Frequent breakdowns and delays are signs that your conveyor systems need to be replaced. Upgrading to newer and more efficient models can have a significant impact on the overall efficiency of your warehouse operations.

Newer conveyor systems will bring in robustness as they are designed with advanced technology that allows for faster processing, increased capacity, and improved reliability. Replacing old conveyor systems at regular intervals will ensure your warehouse is equipped with the latest features and capabilities.

This will not only help streamline operations but also reduce maintenance costs in the long run. However, do not ignore factors like load capacity, speed, flexibility, and energy efficiency before updating to a new system. The replacement process must be done from time to time and should be done only after experiencing breakdowns. 

6. Consider a variable frequency drive

A variable frequency drive or VFD, is an electronic device that controls the speed and torque of an electric motor. It allows for precise control over its operation by adjusting the frequency and voltage supplied to the motor.

A VFD can improve the efficiency of your warehouse conveyor system considerably. It can also reduce power consumption by matching motor speed to load requirements, eliminating wasted energy when operating at full speed is not necessary.

This results in lower electricity bills and reduced environmental impact. Another advantage is increased equipment lifespan as these devices start motors gradually instead of abruptly. Thus, reducing the wear and tear on mechanical components such as belts and bearings.

This leads to fewer breakdowns and maintenance costs. Additionally, a VFD provides greater control over system operations allowing easy adjustments in conveyor speeds based on product flow or production demands.

7. Keep Your Conveyor System Clean

This might seem to be a silly and common point. However, the importance of the same cannot be emphasized enough. Over time, dust, debris, and other contaminants can accumulate on the belts and rollers, leading to increased friction and decreased performance.

Implementing a regular cleaning routine can prevent these issues and ensure that your warehouse conveyor system operates at optimal levels. You can ensure this by conducting routine checks for any signs of dirt or debris buildup. Lubrication is another unavoidable step.

The responsibility of a warehouse facility lies in timely delivery and smooth operation. Following these steps will make sure your warehouse conveyor systems are running just fine and provide you with the desired outcomes.

The efficiency of such systems goes beyond just functioning continuously. It also extends to durability, functioning round the clock without breakdowns, and saving energy. This will result in building up a great reputation, large client base, and huge profit.


A 2004 batch Mechanical Engineering graduate From NIT, Agartala. Close to 16 years of experience in the field of consumer electronics and appliances domain as a Sr. Design Engineer and Team Leader in India and the United States. A GD&T practitioner, with expertise in Lean Manufacturing and Six Sigma. Crazy about exploring CAD-CAM tools and in his free time love to go for a ride with his champ, Rian.