Conveyor
Also called: pallet conveyor, roller conveyor, chain conveyor
A pallet conveyor moves loaded pallets on driven rollers or chains instead of a forklift. The pallet's bottom deck is the running surface, so the orientation of bottom boards, flatness, deflection and condition decide whether it runs reliably.
In depth: Pallets for automation: conveyors, AS/RS and robotic palletizers
Conveyors are common at palletizers, stretch wrappers, and inside automated warehouses. The pallet rides on its bottom deck, so a pallet that works on forks can still jam a conveyor.
Conveyor types and what they need
| Type | What the pallet rides on | Bottom deck need |
|---|---|---|
| Roller conveyor | Rollers across the direction of travel | Bottom members running in the direction of travel, long enough to span several rollers |
| Chain conveyor | Two or three chains along the direction of travel | Bottom members running across the chains, bearing on each chain |
| Pallet flow lanes | Gravity rollers | As roller conveyor |
A common rule of thumb for roller conveyors is that the pallet should rest on at least three rollers at all times. The conveyor maker's pallet specification is authoritative.
Why it matters
- Orientation: bottom boards that fall between rollers, or run parallel to chains, stall or tip.
- Flatness and deflection: sagging bottoms drag; automated systems often require 0.5 in (13 mm) deflection or less.
- Condition: missing or loose bottom boards and protruding nails cause jams. Recycled pallets with bottom damage are a common source.
- Dimensional consistency: guides and sensors need a consistent footprint.
On a spec sheet or RFQ
State the conveyor type, direction of travel relative to the pallet, roller diameter and pitch or chain spacing, and any flatness or deflection limit. The automation guide lists the rest.
Common confusions
A pallet described as "conveyable" by one site may not suit another's conveyor. Always match it to the actual equipment.
Related
- GuidesPallets for automation: conveyors, AS/RS and robotic palletizersAutomated systems need consistent, flat, stiff pallets. Bottom boards must cross the conveyor supports (perpendicular to rollers, across chain strands), gaps must not snag, flatness is often held to 1/4 in or better, and AS/RS racks commonly limit sag to 0.5 in. Perimeter-base block and plastic pallets run either way.
- GlossaryAutomated storageAutomated storage, often called AS/RS (automated storage and retrieval system), stores and retrieves pallets with stacker cranes, shuttles and conveyors instead of forklift drivers. It needs pallets with tight dimensional tolerances, low deflection (often 0.5 in, 13 mm, or less) and sound bottom decks.
- GlossaryBottom deck (pallet)The bottom deck is the lower layer of deckboards (or a perimeter, runner or panel base) on a double-face pallet. It spreads the load onto the floor, rack or conveyor and stabilizes the stringers or blocks.
- GlossaryDeflectionDeflection is the amount a pallet bends or sags under load, measured at the point of greatest movement. Racking limits are commonly about 2% of the span, and automated systems often require 0.5 in (13 mm) or less.
- GlossaryPallet flow rackA pallet flow rack is gravity racking where pallets ride on slightly inclined roller lanes from the loading aisle to the picking aisle, giving first in, first out rotation. The pallet's bottom deck rides directly on the rollers.
More in Handling and storage
- GlossaryBlock stackingBlock stacking is storing unit loads directly on top of one another on the warehouse floor, in rows and columns, with no racking. The bottom pallet and the packaging carry the whole stack, so static load and box compression strength limit the height.
- GlossaryDrive-in rackA drive-in rack is high-density racking where the forklift drives into a lane and places pallets many deep on continuous rails along each side. The pallet is supported only along two edges, so its capacity across the unsupported direction governs.
- GlossaryEdge protectorAn edge protector, or corner board, is an L-shaped strip of laminated paperboard, plastic or other material placed on the vertical or top edges of a unit load. It spreads strapping and stretch wrap pressure, protects case corners, and can add vertical stacking strength.
- GlossaryFork tinesFork tines are the two steel arms on a forklift or pallet jack that slide into a pallet's openings to lift it. Their width, thickness, length and spacing set the minimum size of the pallet's openings and affect its dynamic load rating.
- GlossaryPallet dispenserA pallet dispenser is a machine that holds a stack of empty pallets and releases them one at a time, usually onto a conveyor feeding a palletizer. It needs pallets with consistent dimensions, flat decks and sound bottom boards.
- GlossaryPallet inverterA pallet inverter is a machine that clamps a unit load and rotates it, often through 180 degrees, so the pallet underneath can be removed and replaced without restacking the product by hand.
Last reviewed 2026-09-24. 272 words.