What Are Smart Conveyor Systems, And Do You Need One?

Conveyor systems have long been a familiar sight in warehouses, fulfilment centres, manufacturing and production facilities. From transporting millions of parcels a day to streamlining food production lines, conveyor belt systems continue to prove their status as ‘indispensable’ across modern material handling operations.

In the UK, the adoption of conveyance systems alongside other automation technologies continues to rise steadily, as businesses accelerate their investment in automated logistics to drive efficiency, enhance safety, and meet the needs of a continual shift in customer demands. According to industry insights, the UK material handling equipment market is expected to grow significantly in the coming years, driven by e-commerce expansion, ongoing labour shortages, and a push towards the integration of sustainable and scalable solutions.

As the use of conveyor systems continues to expand across industries, it’s important to understand the different types of conveyors available and how each one supports specific operational needs. From simple belt systems to modular components like roller and overhead conveyors, the right solution depends on the application, throughput demands, and environment.

Common Types of Conveyor Systems in Use Today

Conveyor systems have adapted and advanced significantly over the years and are available in a vast array of configurations, each tailored to specific materials and workflow requirements. Some of the most common conveyor systems in use today include:

a conveyor as a conveyor systems warehouse

Belt Conveyors

Belt Conveyors are ideal for transporting items across horizontal or inclined paths – common in retail, grocery, and parcel handling, especially when variable belt speeds are required for throughput control.

Roller Conveyors

Roller Conveyors are best suited for heavier loads, often used in manufacturing and distribution centres.

Modular Plastic Belt Conveyors

Modular Plastic Belt Conveyors are frequently used in food, beverage, and healthcare sectors due to easy cleaning and customisation.

Overhead Conveyors

Employed in automotive and manufacturing industries where floor space is at a premium.

Spiral Conveyors

Spiral conveyors are utilised where vertical space is needed, often found in e-commerce and postal sorting.

These systems have long been a valuable part of logistics and production infrastructures, but now they’re heading to another level altogether by getting smarter.

What Makes a Conveyor System “Smart”?

A smart conveyor system combines traditional material handling with intelligent automation, sensor technology, motion control, and connectivity. These systems are designed to evolve conventional material movement into intelligent product flow management with adaptive responses and data-driven decisions.

Smart conveyor systems go beyond moving goods from one location to another; they are equipped to optimise every step of that journey.

Here are some of the key technologies that transform a standard conveyor system into a smart one:

Sensors and IoT Integration

Smart sensors detect product size, weight, temperature, orientation, and location, sending real-time monitoring data to central control systems.

AI & Machine Learning

AI can analyse operational data to predict maintenance needs, identify bottlenecks, and optimise routing in real-time.

Automated Sortation Systems

Integrated machine vision and barcode/RFID scanners enable precise and high-speed sorting while improving quality management outcomes.

Programmable Logic Controllers (PLCs) and SCADA Systems

These provide centralised control over multiple conveyor elements and allow dynamic system reconfiguration for better motion control and system flexibility.

Energy Management Systems

Intelligent power usage tracking and on-demand activation reduce energy costs.

Cloud Connectivity & Remote Access

Operators can access performance metrics, diagnostics, and alerts from anywhere, improving visibility and response times.

Smart conveyors bring advanced technology into play, representing a significant and invaluable shift from reactive to proactive management of operations.

Sector Applications for Smart Conveyor Systems

With smart conveyors becoming more intelligent and versatile as technology advances, their adaptability enables them to be used across a wide range of UK industries for a variety of critical material handling applications:

healthcare conveyor

Retail & E-commerce

Retail & E-Commerce requires fast and accurate order fulfilment, real-time tracking, and reduced returns. These benefits are achieved through advanced inventory management systems and automated verification technologies.

Post & Parcel

High-speed automated sortation and dynamic routing systems reduce manual handling and boost throughput while enhancing product flow consistency.

Grocery & FMCG

Grocery & FMCG sectors rely on temperature-controlled conveyors, AI-based inventory management, and minimal product damage. These features enhance perishable goods handling and improve shelf-readiness.

Manufacturing

Manufacturing environments depend on synchronised conveyor integration with robots and CNC machines. These solutions support lights-out production and just-in-time delivery through precise motion control and belt speed management.

Healthcare

Healthcare systems use cleanroom-friendly smart conveyors to automate sample handling and medication distribution. These conveyors ensure compliance, traceability, and reduced human error in clinical environments.

Why Invest in a Smart Conveyor System?

As technologies continue to advance, creating increasingly intelligent conveyors, investment in a smart conveyor system offers a combination of efficiency and adaptability to future-proof operations. Upgrading to a smart conveyor system is more than taking a technological leap forward; it’s a vital strategic move for long-term competitiveness.

Here is just a selection of the many reasons why it’s worth considering smart conveyor integration:

Increased Throughput

Smart conveyors can process more items in less time with greater accuracy, enabling faster order processing and delivery.

Labour Cost Reduction

By automating repetitive tasks, businesses can redeploy human workers to higher-value roles, reduce dependency on manual labour in a challenging employment market, and improve workplace safety.

Real-Time Operational Visibility

Integrated sensors and cloud platforms provide managers with real-time monitoring of system performance, error alerts, and predictive maintenance insights.

Improved Accuracy and Quality Control

Smart systems can verify weights, detect mislabels, and reject damaged goods before they leave the facility, enhancing quality management across the supply chain.

Scalability and Flexibility

Modular components allow smart conveyors to be reconfigured and scaled to meet seasonal spikes, product changes, or growing demand. This can be vital for fast-moving industries such as e-commerce, which are often impacted by the supply chain as well as consumer and seasonal demand.

Energy Efficiency

On-demand power usage, automatic sleep modes, and smart start/stop functions contribute to lower energy bills and improved sustainability.

Using the very best technology solutions on the market, smart conveyor systems offer significant operational advantages, from higher throughput to real-time monitoring and actionable data insights. By enhancing accuracy, improving quality management, and providing scalability to adapt to changing business needs, the benefits wholeheartedly support the business case for investment.

Do You Need a Smart Conveyor?

If your business is struggling to cope with rising order volumes, hiring and retaining workers, or inefficiencies across logistics operations, a smart conveyor system provides a robust, reliable, and transformational opportunity. From handling thousands of parcels daily to striving for zero-error production runs, smart conveyors offer scalable, future-ready automated logistics that adapts with your business, regardless of size and complexity.

As UK industries continue to integrate advanced technology into almost all facets of operations, smart conveyor systems provide a tangible solution that delivers that much-needed competitive edge.