In this article, we take a look at how automation is reshaping how conveyor systems work – not just by moving things faster, but by changing how entire facilities operate. It’s not about replacing people; it’s about letting technology do the heavy lifting, literally and metaphorically, so skilled workers can focus on smarter, safer tasks.
What is Automation in Conveyor Systems?
An automated conveyor system helps improve the movement and handling of products. It means more intelligence, consistency and less reliant on human input. It combines sensors, control software, data collection and, in some cases, robotics to create a conveyor system that can think for itself.
This could be a simple system that slows the belt when it senses a blockage or something more complex, like a conveyor that adjusts speed in real-time based on production demand. Some systems can track individual items, adjusting spacing and orientation automatically depending on what’s needed at the next stage.
Why it Matters
There’s a lot of hype around automation, but let’s talk about real world impact.
In the food industry – automation could result in fewer product recalls thanks to better handling and tracking.
In pharmaceuticals – it can help reduce contamination risk by removing unnecessary human touchpoints.
And in beverages – automation is designed to keep up with the massive output demanded by global supply chains – without any bottlenecks.
The key here is that automation doesn’t just improve throughput. It supports hygiene, traceability, and operational consistency – critical in regulated sectors like food and pharma.
3 Things Automation Can Do That’s Often Overlooked
1. Future Proof Factories
Many production lines run multiple product variants. Traditionally, this meant stopping the line and manually adjusting the system. Automated conveyors now allow rapid, software driven changeovers. This means less downtime and more flexibility to respond to consumer trends, limited editions, or seasonal shifts without halting production.
2. Provide Safer Conveyor Systems
Safety is one of automation’s biggest, but least talked about, wins. Sensors can detect blockages or misaligned products and stop the system immediately. Automated systems can spot anomalies and remove unsafe items from the line. What’s more, there’s a lot less manual lifting and sorting required, reducing the risk of repetitive strain injuries among staff.
3. Aid Staff Shortages
Many companies struggle to hire enough staff, especially for repetitive or physical jobs. Automated conveyors can take on dull, tough tasks, allowing real people to focus on work that needs human skill, such as quality checks.
How to Spot a Conveyor That’s Ready for Automation
Sometimes, the best time to automate isn’t obvious. Here are a few signs your production line may be ready:
- Frequent breakdowns that stop production.
- Manual interventions to keep things moving.
- Difficulty scaling up without adding more labour.
- High error or contamination rates in product handling.
These aren’t failures; they’re signs your system is doing its job but could do it better with some digital support.
Common Challenges when Automating Conveyors
Automation is powerful, but it’s not plug-and-play. One challenge is integration – making sure new automated conveyors talk properly to older equipment or existing software.
Then there’s complexity. Highly automated systems require regular calibration and occasional retraining of staff to understand how the systems behave. It’s why we would advise to start small, prove value, and scale gradually. Don’t try to automate everything overnight.
What Does the Future of Automated Conveyors Look Like?
We’re starting to see AI (artificial intelligence) get involved. AI can look at all the data from your line and make suggestions. It might spot patterns humans would miss. For example, it could find that products move slower every Friday afternoon – maybe due to staff fatigue or layout issues.
Also, energy saving tech is growing. Smart conveyors can now adjust their power use based on how full the line is. This cuts costs and helps with green targets. According to the International Energy Agency, smart manufacturing could cut industrial energy use by 20% by 2040 (source). That’s a big deal.
How to Get Started with Automation?
Start small. You don’t need to rebuild your whole plant overnight. Adding sensors, timers, or basic PLC controls (short for programmable logic controller) can already make a big difference. You can then build up to more advanced systems over time.
Working with a supplier that understands your needs (such as ourselves) can help you find the right setup. Every plant is different. Your layout, product type, and output levels all matter when choosing the right tech.
So if you’re looking to modernise your conveyor systems, feel free to get in touch today on 01543 675800. We’ll help you find the right fit for your line. Because sometimes, the smartest automation starts with a good conversation.