Roller Conveyor vs Belt Conveyor: What is the Difference?

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Choosing the right conveyor system is crucial when optimising your material handling processes. Two of the most common types are roller and belt conveyors, each with unique advantages and applications. Understanding the key differences between these systems can help you make an informed decision that best suits your operational needs.

Our blog will examine the specifics of roller and belt conveyors, comparing their design, functionality, and typical uses to help you determine which best meets your requirements.

What is a Roller Conveyor?
What is a Belt Conveyor?
Roller vs. Belt Conveyor Uses
FAQs

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What is a Roller Conveyor?

A roller conveyor is a material handling system that transports goods from one point to another using a series of cylindrical rollers mounted on a frame. The rollers are typically placed at equal intervals along the conveyor’s length, allowing items to move smoothly across the surface. Depending on the design, roller conveyors can be powered or gravity-operated.

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Types of Roller Conveyors

1. Gravity Roller Conveyor

Gravity roller conveyor systems use gravity force to move items. They are often used in workplace applications where goods must be moved down a slope. A gravity roller conveyor requires no external power source, as the movement of the goods relies solely on the effect of gravity on weighted items. They are suitable for transporting goods short distances.

2. Powered Roller Conveyor

Each roller is powered by a motor, belt, or chain, allowing for the controlled movement of items from one place to another. A powered roller conveyor is suitable for more complex applications requiring precise control over speed and direction. This roller conveyor type can handle heavier loads travelling longer distances and can be integrated easily with automated systems.

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Key Features of Roller Conveyors

Versatility: Roller conveyors can handle various items, including boxes, pallets, and trays, making them suitable for many industries.
Scalability: They can be configured in various lengths and widths, and additional features like curves and junctions can be added to enhance their material handling abilities.
Durability: Roller conveyors are often made from robust materials like steel, and they are built to withstand heavy loads and harsh conditions.

What is a Belt Conveyor?

A belt conveyor system is a type of material handling equipment that uses a continuous belt to transport goods or materials from one location to another. The belt, typically made of rubber, fabric, or metal, is looped around two or more pulleys. One of these pulleys is usually powered by a motor, causing the belt to move, and the other pulleys, known as idlers, help to support the belt and maintain tension.

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Types of Belt Conveyors

1. Flat Belt Conveyor

The most common type of belt conveyor system uses a flat belt to transport items over a flat surface. Flat belt conveyors are suitable for light to medium loads across assembly lines for packaging purposes or the transportation of goods.

2. Inclined/Declined Belt Conveyor

This type of conveyor belt is designed to move goods between different heights, meaning it can be set at an incline or decline where items need to be transported from one level to another. It can withstand various loads and is useful in warehouses and factories with multiple floors.

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Similarities and Differences Between Roller and Belt Conveyor Systems

The table below highlights the key similarities and differences in features and applications between roller and belt conveyor systems.

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	Standard Belt Conveyor	Roller Conveyor
Suitable for cast/tote handling	✅	✅
Suitable for small or irregular items	✅	–
Can be easily modified or added to	–	✅
Accumulation	✅*	✅
Suitable for inclines/declines	✅	–
Stand-by Modes	✅	✅
Energy efficient	–	✅**
Integration with merges	✅	✅
Integration with diverts	–	✅
Low Maintenance	✅	✅
Systems can include bends	✅	✅
Sortation	–	✅

* Limited functionality

** Motorised roller/gravity

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Roller vs. Belt Conveyor Uses

Choosing between a roller conveyor system and a belt conveyor system depends on your application’s specific needs, including the type of materials being handled, the required speed, the environment, and the level of control needed over the movement of items.

When Should I Use a Roller Conveyor?

1. Accumulation Needs

Roller conveyors, mainly accumulation conveyors, are suitable when items need to be queued up or accumulated at specific points along the conveyor without goods ever coming into contact with each other. This is common in packaging, sorting, and assembly processes.

2. Transportation of Flat and Sturdy Items

Roller conveyors are ideal for transporting items with a flat and rigid bottom, such as boxes, crates, and pallets. The items must be big and stable enough to move smoothly over the rollers without falling between each roller.

3. Heavy Loads

Roller conveyors are more suitable for moving heavy or bulky items, such as machinery parts, steel containers, or large pallets, because they can support substantial weights.

4. Human Ease of Interaction

Roller conveyors are more accessible for operators to manage. Due to a lower coefficient of friction than a conveyor belt system, they can swiftly push, pull, rotate, or remove products.

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When Should I Use a Belt Conveyor System?

1. Items with Irregular or Small Bottoms

Belt conveyors are ideal for transporting items with irregular, soft, or small bottoms that wouldn’t move well on rollers, such as bags, packages, loose items, or fragile goods.

2. Steady & Controlled Movement

When items need to be transported at a constant speed without any gaps between them, a belt conveyor provides a continuous, smooth surface that ensures steady movement. This is particularly important in assembly lines and food processing.

3. Transporting Goods over Inclines and Declines

Belt conveyors are better suited for moving items up or down inclines. The continuous surface prevents items from slipping, especially when equipped with cleats or other gripping features.

4. Long Distance Transportation

Belt conveyors are more efficient for transporting materials over longer distances, particularly when a continuous, uninterrupted flow of materials is needed.

Explore Conveyor Systems with CSL

At Conveyor Systems Ltd, our team is well-versed in the conveyor system types and which will best suit your specific requirements.

We have installed belt and roller conveyors in many different facilities, including factories and warehouses, and they have been used to handle a wide range of products, from very light polybags to heavy totes and cartons.

With our tailored solutions and commitment to excellence, we help you enhance the efficiency and productivity of your workplace with our exceptional conveyor systems, allowing you to stay ahead in today’s competitive marketplace.

Contact our team today; we will guide you through choosing the right conveyor system.

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Roller Conveyor vs. Belt Conveyor FAQs

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Yes, both systems can be integrated within the same facility. For example, a belt conveyor might transport items to a certain point, and then a roller conveyor can take over for sorting or accumulation.

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Roller conveyors generally require less maintenance than belt conveyors, especially in rugged environments. Belt conveyors, however, need regular inspection for belt wear, tensioning, and cleaning, particularly in applications involving food or bulk materials.

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Belt conveyors are typically better for high-speed operations because they provide a continuous surface that can move items quickly and steadily. Roller conveyors are more suitable for slower speeds, especially when accumulation is needed.

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Both systems are highly customisable. Roller conveyors can be adapted with curves, merges, and different types of rollers, while belt conveyors can be customised with various belt materials, cleats, and sidewalls to handle specific materials or operating conditions.

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