Vertical Conveyor Systems: Solving the High-Density Challenge

There has been much in the news over the past few years regarding the dwindling amount of warehouse space. Its availability on an island infrastructure such as the UK comes at a premium, so the pressure on logistics and material handling systems to evolve has never been higher. One type of material handling seeing a rise in adoption across the UK and globally is the vertical conveyor system. Designed to move goods efficiently between different building levels, these systems are solving the high-density storage and throughput challenges facing modern operations by enabling the vertical transportation of a wide range of goods.

Why Vertical Conveyor Systems Are Growing in Popularity

The UK warehouse market has seen a boom in demand for space, with e-commerce fuelling record-high requirements for onshoring of goods to support a fragile supply chain, and customer demands for a wider range of SKU profiles and faster delivery times. Yet availability remains limited. According to Savills, warehouse vacancy rates fell below 4% in 2024, pushing businesses towards a very real need to optimise the floor area they currently hold.

This is where vertical conveyor systems offer a robust solution to help businesses maximise the available footprint of the building. By transporting goods vertically rather than horizontally, they optimise space usage in high-density environments such as multi-level distribution centres, mezzanine storage areas, and manufacturing facilities, which often have limited floor space for stored goods. These applications in conveyor systems support a safe working environment and help reduce operating costs through automation integration. Importantly, vertical conveyors enable businesses to scale operations upward, preserving valuable ground-level square footage while maintaining or even increasing throughput.

Types of Vertical Conveyor Systems and Their Benefits

There are several types of vertical conveyor systems available for small, medium and large-scale operations, each tailored to specific applications, loads, and throughput requirements.

Vertical Reciprocating Conveyors (VRCs)

Vertical reciprocating conveyors are essentially material lifts that move goods between floors using a reciprocating motion: a repetitive, back-and-forth or up-and-down movement along a straight line. VRCs can be custom-built to any height and typically transport palletised loads, totes, and cartons with a load capacity ranging from 100 kg to several tonnes. Their modular design supports compact design requirements and allows for minimal maintenance. They are more cost-effective compared to freight lifts, offer a space-saving solution particularly suited to mezzanine access, and integrate easily with Roller Conveyors and other types of conveyor systems. Vertical reciprocating conveyors are commonly found in warehouses, retail operations, and manufacturing facilities handling heavy pallets and bulky loads.

Continuous Vertical Conveyors (CVCs)

Continuous Vertical Conveyors move products in a continuous loop, typically using slats or trays attached to a chain conveyor or belt system. CVCs offer a high-speed, uninterrupted flow of material, transporting goods up or down simultaneously with a minimal floor footprint. Continuous vertical conveyors provide a high level of throughput, safe handling of fragile or gentle product types, and are low maintenance due to fewer moving parts. Safety features such as safety sensors ensure compliance with safety standards. CVCs are widely used in e-commerce fulfilment, food and beverage processing, and applications with load capacity needs.

Spiral Conveyors

Spiral Vertical Conveyors are designed to move products along a helical path, combining vertical transport with accumulation to reduce the potential for bottlenecks. They are compact in design, taking up minimal horizontal space, can handle continuous or intermittent flow of material, and are available in belt or roller configurations. This conveyor product vertical supports a wide variety of product sizes, ideal for automated production lines and packaging areas. Spiral conveyors are suited for assembly operations in tight warehouse environments and are commonly used for packaging lines, bottling plants, and food production facilities.

Vertical Lifts (Pallet Lifts and Tray Lifts)

These systems move goods vertically using motorised shuttles or robotic mechanisms. They are typically used in advanced production lines such as Automated Pallet Shuttle systems and support integration with Warehouse Management Systems. Vertical lifts are ideally suited for high-density, high-value operations, providing seamless automation integration with robotics and shuttle systems to enhance order accuracy, speed, and precision. Their drive motor systems ensure accurate load transfers with minimal human intervention. They are commonly found in the automotive industry, pharmaceuticals, and electronics distribution.

Incline Conveyors

Incline belt conveyors use a sloped belt or roller system to move goods between elevations, commonly used for short vertical transfers. They feature an adjustable incline angle available in flat, cleated or troughed belt options and can be modular in design. Incline conveyors offer a simple and cost-effective option for moderate height changes, helping maintain a safe working environment while transporting heavy loads and a wide product range. Incline conveyors are used in Distribution Centers, sortation depots, and bulk-handling applications requiring moderate elevation change.

Automation Technologies That Integrate with Vertical Conveyors

To unlock the full benefits of vertical conveyors, many organisations are combining them with other automation technologies to create seamless material handling equipment solutions. The most common include:

Automated Storage and Retrieval Systems (AS/RS)

ASRS supports vertical conveyor lift systems for storing raw materials and retrieving goods over multiple levels.

Robotic Picking Systems

Picking Systems are used for precise picking of heavy equipment and gentle product types, enhancing the fulfillment process.

Warehouse Management Systems (WMS)

WMS manage and track a wide variety of products across conveyor lines and vertical conveyor types.

AMRs and AGVs

Autonomous Mobile Robots and Automated Guided Vehicles support transport of unit loads between levels.

RFID and Barcode Scanning

RFID ensures traceability and helps reduce risk of contamination across product verticals.

The Future of Vertical Conveyors in the UK

As urban warehouse development intensifies and same-day delivery becomes standard, vertical conveyor systems will continue to gain traction. Their application in a wide range of industrial application settings, including agricultural operations and bulk material conveyors, allows for scalable automation solutions that minimise additional costs and future-proof warehousing operations. By investing in vertical conveyor solutions such as L-shaped conveyors, vertical belt conveyors, or spiral conveyors, businesses can reduce their reliance on human labour, enhance safety across automated operations, and improve the transport of products between levels. For companies aiming to reduce drive base complexity with single drive systems, these systems support minimal maintenance and offer broad applications across logistics. Vertical Conveyor Solutions represent a commitment to safety, accuracy in warehouse operations, and handling heavier loads across varied product types and applications without load bearing. Whether the goal is reduced operating costs or an adaptable system for automation integration, vertical conveyors offer a bespoke solution to modern warehouse automation challenges.