Accumulation Conveyors – Benefits of Zero Pressure vs. Minimum Pressure Applications

Accumulation Conveyors Offer Cost-Effective, Versatile Warehouse Automation

Accumulation conveyors are automated conveyor systems commonly used to transport, collect, and redirect goods. However, they can also be used for product counting, labeling, and packaging. Their unique feature  – as the name implies – is the ability to accumulate products, meaning the conveyor can collect items to create a buffer zone allowing upstream equipment to function while a downstream conveyor has stopped. When the downstream conveyor restarts, the accumulation conveyor feeds items back into the flow, enabling the accumulation conveyor to handle high-volume orders with high efficiency. 

Accumulation conveyor offer many benefits, such as streamlining the sorting process, reducing processing costs, and increasing worker safety, allowing customers to recover their capital investment quickly. 

They are available in several types: roller, belt, wheel, and chain conveyors, and they are customizable, allowing users to adjust the speed and size of the belt or chain to match any application. With their versatile design, these conveyors can help increase productivity and enable businesses to manage their inventory flow effectively.

Advantages of Accumulation Conveyors:

• Enable smooth, efficient product flow without disruption
• Minimize backlogs and jams from incline and spiral systems 
• Customizable to different inventory shapes and sizes
• Application variety, including sorting, merging, and packaging
• Help to reduce labor & energy costs
• Improve worker safety by minimizing forklift travel & repetitive motion activity

Applying the Right Amount of Pressure

Accumulation conveyors typically come in two varieties: Zero Pressure Accumulation (ZPA) or Minimum Pressure Accumulation (MPA). While the difference between the two seems subtle, it may be the essential feature you need, given your inventory handling risks and requirements.

Zero Pressure Conveyors

Zero-pressure accumulators minimize contact between products, allowing them to accumulate without touching. Using an array of sensors, the conveyor stops until the first item in the queue is released. They use minimal energy to move materials from one point to another without pressure or friction. 

These systems are fitting for applications where products or packaging is sensitive, fragile, and requires gentle handling, i.e., food items, high-end goods, and medical supplies. Packaging that is colored is ideal for zero-pressure conveyors to prevent damage to the finish. You will often see zero-pressure accumulators in distribution center packaging areas because they allow workers time to pack and check each order without creating a disorganized backlog. 

To optimize your warehouse space and function, you can design your conveyor line to move products in a straight, curved, or inclined path. This system offers reduced maintenance costs, improved safety, and greater efficiency than traditional conveyors. 

Benefits

• Lower cost per item moved
• Minimal training to operate
• Regulates item flow rate
• Noise-reducing
• Customizable – standard, heavy-duty & pallet models

Uses

• Conveys varying item sizes & weights
• Prevents carton and inventory damage
• Packing & quality control stations
• Assembly

Minimum Pressure Conveyors

Minimum pressure accumulation conveyors allow items to lightly touch with minimal back pressure forces, typically between 2% – 5% of the total live load. Interconnected rollers with sensors detect when an item is present on the conveyor activating the rollers to move it in a specific direction with only enough force to keep it moving. 

When setting up your system, the challenge is to create a smooth flow speed with enough power to move the heaviest items while managing the back pressure forces. This low-pressure operation allows the gentle handling of sensitive items while providing efficient transportation. Minimum pressure accumulation conveyors are an ideal choice for businesses that require efficient transit of sensitive items.

Benefits 

• Less expensive than zero-pressure systems (approx. <50%)
• Higher throughput rates than zero-pressure systems
• Low maintenance

Uses

• Smaller, consistent load sizes and weights
• Straight, non-curved routes
• Ideal for short distances to minimize back pressure
• Queue products for sorting, palletizing, etc.

Industries that Frequently Use Accumulating Conveyor Technology

• Food production
• Automotive manufacturing
• Retail
• Logistics
• Packaging
• Parcel services

Accumulation conveyors can be a valuable warehouse asset as part of your automated material handling system. Different types of accumulation conveyors, such as zero-pressure and minimum-pressure models, offer improved safety, reduced maintenance costs, and greater efficiency when compared to traditional conveyors. 

Whether you’re looking to move food items, retail products, or medical supplies, the Warehouse Optimizers, Inc. (WOI) team will configure your conveyor system to suit your needs. Our team will also ensure that it is integrated into your operation to provide the most cost-effective results.

The WOI team offers over 180 years of combined material handling experience, and we are dedicated to delivering 100% Customer Satisfaction on every project.

Take a look at our Total Satisfaction Experience™ (TSE) commitment to our customers.

The Total Satisfaction Experience focuses on five essential customer experiences:

1.  We will listen to your needs
2.  Execute your project with particular attention to your unique application
3.  Stick to project timelines
4.  Ensure a safe environment
5.  Pay close attention to the detail of the finished product

Your project installation couldn’t be in better hands. Our professional installation team is committed to safety while operating in your facility, and we aren’t finished until the final project meets your expectations.

WOI Installation Team

• OSHA Trained & Certified
• Certified Drug-Free Workplace
• Licensed General Contractor
• Job Safety Analysis
• Forklift, Scissor Lift, and Aerial Lift Operator Trained

Call WOI today for a free consultation and schedule a site inspection — dial (833) 336-7005 or email info@warehouseoptimizers.com. 

WOI proudly serves customers throughout the Southeast, including KENTUCKY, TENNESSEE, NORTH CAROLINA, ALABAMA, AND FLORIDA.