An often overlooked solution to material-handling tasks that change frequently is the modular conveyor system, according to Muskegon, Mich.-based Dynamic Conveyor Corp., (dynamicconveyor.com). The company says modular units improve process flow, reduce labor, and nearly eliminate the cost of replacement conveyors.

“As the name suggests, modular conveyors come in sections that can be reconfigured to change shape quickly,” says company spokesman Tom Habetler. Interlocking sections are made of lightweight, high-impact polycarbonate and include belts, sides, legs, motors, and accessories. What's more, the units need no lubrication,” he adds.

Habetler says such conveyors are “legos for packaging engineers” in that they help meet changing production flow in light to medium-duty environments. “Adjustable leg sets and casters allow for easy changes,” he adds. The systems are normally limited to handling products that are less than 15 lb in weight. However, if robots are used to gently place products on a conveyor, it can handle weights of 15 lb or more.

One module comes with ribbed sides that can be “bent” or flexed for a turn of any radius, up to 180°, and it can flow on an incline or decline. This feature lets product moves on a single conveyor with a single motor rather than two fixed conveyors with two motors.

Belts come in several materials and configurations. They are compatible with a variety of Introlox link style belting. “Options here include flat top and perforated, grid, friction and radius-turn designs,” says Habetler. Standard belt material is an impact-grade polypropylene. Optional materials include acetyl, polyethylene and nylon. Belts are available in widths from 4 to 60 in. Drive flights can be installed at any location along the belt and are available in 1, 2, and 3-in. heights, in widths to fit belt widths.

Accessories include box fillers, cooling tunnels, separators, and water-bath tanks for cooling products carried by the conveyor. One design for clean rooms meets ISO Class 3 clean-room standards (Federal Standard 209E Class 1). Its lightweight plastic modules make it easy to clean and move, and it has smooth bidirectional motor that makes no emissions.