Custom versus standard conveyor systems: which is best for your business?

Across the industrial landscape, conveyor systems continue to play a pivotal role in streamlining warehouse, distribution, manufacturing and production facility operations. From moving palletised goods in a warehouse, order processing and packaging of fashion items for an e-commerce fulfilment centre, or high-speed sortation for post and parcel operations, conveyors are an essential element in improving efficiency and reducing the reliance on a dwindling pool of available labour. Modern conveyor systems, such as incline conveyor designs or accumulation conveyors, cater to a variety of industries, enhancing operational efficiency at every stage.

However, businesses often face a critical decision: Should they opt for a custom conveyor system tailored to their specific needs, or rely on a standard conveyor system that offers tried-and-tested, reliable functionality? Evaluating application parameters and understanding the unique requirements of production operations is crucial when making this decision.

Key Industry Insights

As a leading systems integrator, L-A-C Logistics Automation offers both custom and standard conveyor solutions for a wide range of industry applications, with outstanding benefits for both. With a deep understanding of conveyor designs and application-specific needs, we provide bespoke conveyor systems as well as modular options that deliver complete solutions. Our latest article explores the types of conveyors available, the differences between custom and standard conveyor systems, and the emerging technologies that look set to support the continuing advancement of conveyor system innovation.

Types of Conveyor Systems

Understanding the types of conveyor systems is essential before assessing the need for either a custom-built solution or more traditional standard conveyor modules. Here we have outlined the primary categories for each of the main types of conveyor systems and the benefits:

Belt Conveyors

Belt Conveyors are commonly used for manufacturing and packaging as they are ideal for moving lightweight to medium-weight materials of varying sizes and shapes. Belted conveyors offer flexibility in conveyor lengths, accommodating different product types efficiently.

Roller Conveyors

Roller Conveyors are extremely robust and ideal for warehouse and distribution centres. They are highly efficient at transporting packages, parcels, heavy goods, and full-sized pallets. The addition of conveyor rollers as accessories for conveyors can improve material flow.

Chain Conveyors

Chain Conveyors are often seen in the automotive industry as well as those using heavy machinery as they are specifically designed for the movement of heavy or bulk items. Chain belt conveyors and roller chain conveyors are particularly effective in these settings.

Screw Conveyors

Screw Conveyors are popular in the food processing and agriculture sectors and are ideally suited to moving raw and bulk materials such as grains and powders. Their straightforward design ensures reliability.

Overhead Conveyors

Overhead Conveyors offer additional space optimisation using the full height of the facility. They are commonly installed for garment manufacturing and distribution, as well as automotive assembly lines.

Vibrating Conveyors

Vibrating Conveyors are usually found in the food and pharmaceutical industries, designed for precise movement of delicate or granular materials. These conveyors often incorporate standout features tailored to specific production requirements.

Custom Conveyor Systems: Delivering Tailored Precision

Custom conveyor systems are designed and engineered to meet the specific requirements of a business’s operations and are sufficiently flexible to benefit applications in any industry sector. Integrating the most appropriate conveyor types for each specific operational process ensures efficiency levels are fully optimised. By addressing special requirements, custom designs can meet even the most complex needs in the manufacturing process. This also future-proofs the chosen solution for changes in product ranges or upscaling throughput as required with minimal disruption to existing operations or the need for additional equipment. A bespoke conveyor can be an invaluable piece of equipment for businesses looking for long-term adaptability.

Advantages of Custom Conveyor Systems

Here are the key advantages and considerations for custom conveyor solutions:

Exact Fit for Unique Needs

Custom conveyors can handle goods with specific dimensions, weights, and speeds, making them ideal for specialised operations or applications handling a wide variety of items. They address a base of conveyor solutions that ensures precision.

Integration with Existing Systems

They can seamlessly integrate with other machinery and automation systems, as well as manual processes to provide a fully streamlined flow of materials across the facility. Whether it’s aluminum conveyors or chain conveyor systems, integration is key.

Scalability

Custom solutions should be designed to take expansion and diversification into account. The resulting conveyor system solution will therefore offer inbuilt agility to grow your business in the long term with minimal disruption and additional investment.

Material Optimisation

The use of materials for custom conveyor system solutions is tailored to the environment. This can vary from corrosion-resistant metals or food-grade plastics to ensure streamlined operations meet strict industry regulations. Custom designs also consider cubic feet capacity for efficient material handling.

Considerations of Custom Conveyor Systems

Higher Initial Costs

Custom solutions typically involve higher up-front design and manufacturing costs, yet are usually more cost-effective long term taking scalability and cost savings into account.

Longer Lead Times

Designing and producing a custom conveyor takes time; however, the installation and go-live period may be shorter as each component is designed to fit seamlessly with existing processes.

Complex Maintenance

Custom systems may require specialised knowledge or parts for repairs, so it’s important to consider an ongoing support and maintenance package from your supplier to include preventative maintenance and readily available spare parts.

Standard Conveyor Systems: Proven and Reliable

Standard conveyor systems are pre-engineered and produced in large volumes, supporting quicker installation periods and also providing easier access to spare parts due to their generic design and modularity.

They are often used for general-purpose applications and offer a host of benefits yet with some limitations. Standard conveyor product lines are especially beneficial for industries seeking cost-effective solutions without compromising reliability.

a conveyor as a conveyor systems warehouse

Advantages of a Standard Conveyor Systems

Cost-Effective

Standard systems are generally more affordable due to economies of scale from large-scale production.

Quick Delivery

With minimal customisation options, standard conveyors are readily available for speedy installation.

Ease of Maintenance

Spare parts and repair services are widely accessible, minimising the potential for operational downtime.

Proven Design

Standard systems are extensively tested and reliable, offering a robust solution for wide-ranging applications. Many include cleated belt incline conveyors, known for their efficiency in transporting goods across various incline levels.

Considerations of Standard Conveyor Systems

Limited Customisation

They may not fit in with specific operational requirements or existing processes. Accessories for conveyors can help mitigate some limitations.

Potential Inefficiencies

Standard designs may not optimise the overall material flow and throughput needed for specialised operations.

Lower Longevity in Specialised Environments

Standard materials may not withstand harsh conditions, such as cold storage or transporting raw materials, as effectively as custom conveyor systems.

Future Trends and Technological Advances

The versatility of conveyor system solutions continues to evolve at pace, driven by advances in technology. From AI to Robotics, here are some of the key trends to watch in 2025:

Smart Conveyors

Integration of IoT for real-time monitoring and diagnostics.
Predictive conveyor system maintenance using AI.

Automation and Robotics

Combining conveyors with robotic systems for advanced material handling.
Integration of autonomous mobile robots (AMRs) to complement operational processes using conveyor systems.

Modular Designs

Increased use of modular components for straightforward customisation and scalability.
Plug-and-play systems offering quick installation.

Energy Efficiency

Adoption of energy-efficient motors and regenerative braking systems.
Solar-powered conveyors for eco-friendly operations.

Advanced Materials

Development of lightweight yet durable materials.
Enhanced corrosion resistance and hygiene standards for food and pharmaceutical applications.

Making the Right Choice for Your Business

With the various benefits and considerations outlined above, making the final decision between custom and standard conveyor systems can seem overwhelming. To help with this process, we have put together a summary of the factors to consider to ensure the best use of investment for your conveyor system. A reliable conveyor manufacturer will provide guidance tailored to your operational needs.

For operational needs, analyse your workflow, material types and requirements for volume. Also, factor in expansion and diversification plans here. When it comes to the all-important budget, determine your up-front investment capital versus the long-term savings, enhanced productivity, and throughput to determine ROI. When looking at the flexibility needed for the conveyor system, assess the level of customisation your operations demand and if bespoke elements can be retrofitted to a standard solution, should the need arise in the future. Scalability and understanding future needs are a vital part of the decision process to ensure the chosen solution delivers efficiency now and in the long term. For applications with strict industry standards, the conveyor system must enable your operations to comply with industry-specific regulations and standards. Conveyor flexibility will be critical in adapting to these evolving needs.

Conclusion

The evidence for custom and standard conveyor systems is compelling as both types of solutions have considerable merits. Custom solutions are ideal for businesses with specialised or complex requirements, while standard systems provide reliable, cost-effective options for general-purpose applications.

By evaluating your specific needs and staying informed about emerging technologies, you can choose the system that best aligns with your current operational needs and future goals. Leading conveyor systems manufacturers can offer insights into a wide array of conveyors, ensuring the perfect fit for your business.