Regardless of the product being assembled, conveyors play a crucial role in mass production. They move components between workstations, help balance production timing by queuing parts at slower stations, and precisely position items for processing.
Here’s an overview of some of the newest conveyors and material handling solutions.
Conveyor Handles Workpieces Up to 3,000 Kilograms
Bosch Rexroth has launched the TS 7plus transfer system—a fully electric, highly customizable conveyor designed for workpieces weighing as much as 3,000 kilograms.
The TS 7plus moves materials using rollers on modular sections that can be tailored to specific needs. Available options include lift-and-transfer units, rotary units, positioning units, and stop gates. With a minimum height of just 350 millimeters for both longitudinal and transverse conveying, the system supports manual assembly and improves worker ergonomics. The standard workpiece pallet size is 2,200 by 3,000 millimeters.
The conveyor section uses either solid or hollow rollers—about 50 percent larger than those in the earlier TS 7 model. Fewer moving parts per meter mean higher uptime, and the redesigned bearing block allows quicker assembly with two mounting tabs in the profile, plus easier replacement during maintenance.
Unlike traditional chain-driven systems, the TS 7plus runs on lubrication-free king shafts that require minimal upkeep. Motor torque is transferred to the rollers via bevel gears, which helps prevent contamination of workpieces. These bevel gears never need re-tensioning or maintenance.
In standard accumulation setups, stop gates hold pallets at designated stations. With the alternative segmented operation mode, motors for section transport, rotary units, and lift-and-transfer units activate only when needed. This boosts energy efficiency and lowers total cost of ownership. Smaller motors can be used, and their demand-driven operation extends service life.
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Bosch Rexroth offers 180- and 250-watt motors for the TS 7plus, along with an interface that supports third-party motor integration.
Motors can be mounted either inside or outside the conveyor section. Internal mounting eliminates protruding contours that could interfere with workers or obstruct travel paths. With speeds reaching up to 24 meters per minute, the system delivers significantly faster transport than automated guided vehicles.
Bosch Rexroth
www.boschrexroth.com
Heavy-Duty Vertical Transfer Unit
Photo courtesy Glide-Line
Glide-Line’s Heavy-Duty Vertical Transfer Unit (VTU) lifts heavy pallets vertically to move them between different levels. This servo-driven unit can raise palletized loads of up to 200 kilograms to heights of 5 meters. Built with a welded, painted steel tube frame and fixed exterior safety panels, it ensures both durability and operator safety.
The VTU is ideal for robotics integration, multi-level assembly lines, and high-mix production environments where precise product flow between elevations is essential.
Featuring steel lifting elements, roller chain transport, and manual chain tensioning, the VTU can be customized to meet diverse application needs. Its modular design enables seamless integration with pallet conveyors, timing belt systems, and broader automation platforms.
The VTU’s precise lift control ensures consistent product presentation for downstream operations such as robotic assembly, inspection, and packaging.
Glide-Line
www.glide-line.com
Conveyor for Medical Device Assembly
Photo courtesy FlexLink
FlexLink has unveiled a smart, puck-based conveyor system tailored for automated assembly and packaging of medical devices like insulin pens. This high-speed solution combines gentle product handling with industrial-grade reliability.
The system carefully transports delicate assemblies—including vials, syringes, and ampoules—by securing each item in a custom puck. This stabilizes products during critical processes such as labeling, inspection, and packaging, protecting them and maintaining proper orientation for subsequent steps.
The conveyor integrates smoothly with existing equipment, including vision systems, robots, and labeling modules. It supports full traceability and real-time data capture, helping manufacturers comply with GMP, FDA, and EU regulations.
Clean, quiet, and energy-efficient, the conveyor is suitable for sterile, cold chain, and freeze-dried products. It can be combined with filling, packaging, and other end-of-line processes. Available modules support line balancing and short-stoppage compensation. Options include built-in workstations, multi-level and multi-lane configurations, and gate systems.
It gently and accurately handles and buffers large product volumes without causing scratches.
FlexLink
www.flexlink.com
Heavy-Duty Belt Conveyor
Photo courtesy QC Conveyors
QC Conveyors has released its widest, longest, and strongest aluminum-frame conveyor yet, built to handle heavy loads across a range of applications. The reinforced frame includes dual T-slots for accessory mounting. It’s highly configurable, easy to maintain, and competitively priced.
The robust aluminum frame is reinforced with steel cross-ties for maximum structural support. Each frame section is securely fastened to these cross-ties to maintain long-term rigidity.
A crowned pulley ensures reliable belt tracking in most applications. Slightly thicker at the center, it leverages the natural tendency of belts to align with the longest part of the conveyor, extending belt life. The frames and pulleys are designed to accommodate optional V-guided belting without modifications—ideal for side-loading and reversing applications where consistent tracking is critical.
A wide selection of cleated and flat belts is available, including multipurpose, high-friction, accumulation, cut-resistant, anti-microbial, static-conductive, color-contrasting, translucent, release-coated, and specialty profiles. Belts come in lengths up to 40 feet and widths of 6, 12, 18, 24, 30, and 36 inches. The conveyor supports loads up to 600 pounds, with a maximum belt speed of 535 feet per minute.
QC Conveyors
For more information on conveyors, read these articles:
Conveyors Remain a Vital Link to Efficiency
Conveyors and Lean
AGVs vs. Conveyors
