Complete Guide to Warehouse Conveyor Systems
How to Invest Wisely in Warehouse Automation for Growth and ROI
Upgrading your warehouse conveyor system isn’t just an operational decision – it’s a financial strategy. The right investment can reduce labour costs, significantly increase throughput, and future-proof your operations, while the wrong one can lead to inefficiencies and wasted capital.
In this guide, our experts will walk you through everything you need to know about warehouse conveyor systems – from understanding the different conveyor types to choosing the right design for your space, estimating costs, and keeping your equipment running smoothly for the long term.
Key Takeaways
- Conveyor systems are strategic investments, not just operational upgrades.
- The right system can reduce labour costs, boost throughput, and scale with your growth.
- Costs range from £50 to £5m+, but ROI is achievable through efficiency gains.
- Maintenance and scalability planning protect your investment long-term.
- CSL provides end-to-end solutions, from design and installation to maintenance
What is a Conveyor System?
A conveyor system is a mechanical solution designed to automate the movement of goods within a warehouse or distribution centre. By replacing manual handling with automated transport, warehouses can process orders faster, reduce workplace injuries, and increase overall throughput.
Upgrading your warehouse with a conveyor system is about more than moving boxes faster. It’s a strategic investment that directly impacts your bottom line.
Why Conveyor Systems are a Strategic Investment
RISING LABOUR COSTS
Warehouse wages are climbing, while skilled staff are harder to find. Automating repetitive tasks helps you control operating costs.
CUSTOMER EXPECTATIONS
Fast, accurate fulfilment is now the norm. A conveyor system helps you increase throughput and accuracy without increasing headcount.
DOWNTIME COSTS
Every minute a warehouse stops moving products costs thousands in lost revenue. Well-designed conveyor systems minimise downtime and delays.
How does this work in practice?
“Our client, *client name*, reduced their labour costs by X% and increased order capacity by X% within 12 months of installing a custom conveyor system.”
By automating key parts of your warehouse process, you’re not just solving today’s challenges – you are future-proofing your operations against tomorrow’s demands.
Why Conveyor Systems Matter
SPEED
ACCURACY
LABOUR SAVINGS
SAFETY
Did you know?
According to the UK Warehousing Association, labour accounts for up to 60% of warehouse operating costs. Investing in automation like conveyor systems can significantly cut these expenses.
Belt vs Roller Conveyors
The two most common types of conveyor systems each serve different purposes. Each conveyor type is custom built to the specifications of your warehouse, taking into consideration current throughput goals and future growth plans.
Best for
Roller Conveyor
Belt Conveyor
Suitable for small packages, poly bags, envelopes etc
Multiple divert and merge options
Can be used for changes of level such as incline or decline
Low maintenance
Easily Reconfigurable
Suitable for fragile items
Accumulation function
When to Choose Belt Conveyors
When to Choose Roller Conveyors
- Perfect for e-commerce operations with lightweight products.
- Low upfront costs and minimal maintenance.
- Fast installation for growing businesses.
- Best for larger warehouses, distribution centres, and e-commerce operations.
- Handles heavy loads like pallets and bulky boxes.
- Reduces reliance on forklifts and manual transport.
Learn more about the difference between roller conveyors, belt conveyors, and conveyor belts in our expert blog.
Designing Conveyor Layouts for Growth
Your conveyor system layout should match your current operations, while preparing for future growth. Whether you are a new e-commerce business with clear operational plans, or a large distribution centre focusing on continued cost-cutting, an automated conveyor system can help you achieve business goals.
SMALL OPERATIONS (<12,000 sq. ft)
- Modular, flexible systems that can expand over time.
- Lower initial investment while maintaining scalability.
- Ideal for startups or seasonal e-commerce businesses.
MID-SIZED WAREHOUSES(12,000 - 60,000 sq. ft)
- Hybrid conveyor setups with basic automation features.
- Dedicated zones for returns, despatch, and sorting.
- Focus on balancing current efficiency with future needs.
LARGE DISTRIBUTION CENTRES(>60,000 sq. ft)
- Fully automated systems with multiple lines and high throughput.
- Integration and advanced software like WMS for real-time-tracking.
- Designed for 24/7, high-volume operations.
Read our case study: Scaling a Large E-Commerce Distribution Centre with CSL.
Protecting Your Investment With Maintenance & Risk Management
If you are considering improving your warehouse operations with a conveyor system from CSL, you need to be informed enough to make financial decisions that consider the total cost of ownership, not just your initial spend.
WHY MAINTENANCE MATTERS
- Prevent unplanned downtime that halts production and throughput.
- Extend equipment lifespan for better long-term ROI.
- Stay compliant with health and safety regulations.
CSL’S MAINTENANCE SOLUTIONS
- 24/7 breakdown support to minimise downtime.
- Scheduled preventative maintenance to avoid major issues.
- Performance audits to optimise efficiency over time.
MAKING A CASE FOR YOUR BUSINESS
- ROI Guide: Simplifies your business case with visuals and key metrics.
- Ready-to-use slides for stakeholder meetings.
- Expert Consultation: CSL’s team can attend meetings or provide custom projections.
CSL offers comprehensive maintenance programmes to keep your system running smoothly.
Why Partner with Conveyor Systems Ltd?
CSL isn’t just a supplier – we’re your strategic partner for long-term warehouse success.
- 28+ years of experience designing and installing systems across the UK.
- Custom-built solutions tailored to your operations and growth plans.
- Ongoing support with maintenance, upgrades, and optimisations.
Your next steps:
- Book a free consultation.
- Explore our case studies.
- Learn more about CSL’s maintenance