Navigating conveyor and automation system integration

Jun 4, 2024

A guide for Operations Directors 

As an Operations Director, you understand the critical role that automation plays in streamlining processes and enhancing efficiency within your facility, whether it’s an ecommerce warehouse, fulfilment centre, or factory. However, embarking on the journey of designing and installing a new conveyor and automation system can seem daunting. To ensure a successful integration process, it’s crucial to establish clear user requirements and effectively communicate your needs to potential integrators. This guide aims to provide you with a comprehensive User Requirement Specification (URS) and equip you with the necessary knowledge to navigate this complex process with confidence.

Conveyor system and racking

Define your objectives

  • What are your primary goals for implementing a conveyor and automation system?
  • Are you aiming to increase throughput, reduce labour costs, enhance safety, or improve accuracy?
  • How do you envision the system integrating with your existing processes and infrastructure?
  • Are there specific performance metrics or Key Performance Indicators (KPIs) that you aim to achieve?


Assess your current workflow

  • Conduct a thorough analysis of your current workflow, including material flow, order fulfilment processes, and labour requirements.
  • Identify bottlenecks, inefficiencies, and areas for improvement.
  • Consider future growth projections and scalability requirements.


Determine system requirements

  • What types of products or materials will be conveyed? Consider size, weight, shape, and fragility.
  • What is the desired throughput capacity of the system?
  • Do you require any specialised features such as accumulation, sorting, merging, check weighing or diverting?
  • Consider environmental factors such as temperature, humidity, and cleanliness requirements.
  • Determine integration needs with other systems such as Warehouse Management Systems (WMS) or Enterprise Resource Planning (ERP) systems.


 Safety considerations 

  • What safety regulations and standards must the system comply with?
  • Identify potential hazards such as pinch points, fall hazards, and collision risks.
  • Specify safety features such as emergency stop buttons, protective guarding, and interlocking systems.
  • Conveyor Systems Ltd will advise on these points but it is imperative that they are factored into your decision making process.


Space and layout

  • Evaluate available space for system installation, including ceiling height, floor space, and any obstructions.
  • Consider layout options to optimise material flow and minimize congestion.
  • Ensure compliance with building codes and regulations.
  • Plan operator ingress and egress around the new conveyor system.


Integration and compatibility

  • Determine compatibility with existing equipment, software, and infrastructure.
  • Assess the need for customisation or integration with third-party systems.
  • Specify communication protocols and data exchange requirements.

Maintenance and support

  • Consider ongoing maintenance requirements and the availability of spare parts.
  • Discuss support options with potential integrators, including training, troubleshooting, and technical assistance.

Budget and ROI

  • Establish a budget for the project, including initial investment costs and long-term operating expenses.
  • Conduct a cost-benefit analysis to determine the return on investment (ROI) of the proposed system.
  • Consider factors such as labour savings, increased productivity, and reduced error rates.
Repairing roller on conveyor


By defining clear user requirements and considering the various factors outlined in this guide, you can effectively communicate your needs to potential integrators and ensure a successful conveyor and automation system integration. Remember to collaborate closely with your chosen integrator throughout the process to achieve optimal results that align with your operational goals and objectives. Conveyor Systems Ltd have a wealth of experience of helping our customers get the most out of their system and can help guide you through the process of designing and installing an automation system from start to finish.

Find out how CSL can help bring your project to life. Contact us on 01283 55 22 55, email or visit our website

We Design, Install and Maintain Conveyor Systems

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