Gravity Conveyor

Gravity conveyors provide a simple, cost-effective way to move cartons, totes, and pallets using the natural force of gravity. With no motors or complex controls, these systems reduce energy use and maintenance while improving material flow across warehouses, distribution centers, manufacturing lines, and shipping areas.

Understanding Gravity Conveyors

A gravity conveyor moves items along a slight decline, relying on gravity rather than powered drives. When a section is set to an appropriate pitch – often 1% to 2% slope for typical cartons, and higher for heavier or less free-rolling loads – products flow smoothly from point A to point B. Facilities often combine sloped runs for travel with level sections for staging, accumulation, and manual control at workstations.
Two primary designs are commonly used:

• Gravity roller conveyor: Steel or aluminum gravity rollers are mounted in a rigid frame to provide continuous surface support. This design handles a wide range of package sizes and weights, making it suitable for order fulfillment, assembly, dock operations, and pallet handling when equipped with larger rollers and higher-capacity frames.
• Gravity skatewheel conveyors: Rows of small wheels mounted on axles provide a lighter, often more portable option that excels with consistently sized, flat-bottom packages such as cartons or totes. These are popular in packing stations, flexible temporary lines, and areas where agility and quick reconfiguration are essential.

Additional variations expand functionality. Ball transfer tables allow omnidirectional movement at workstations for inspection or reorientation. Curves, spurs, merges, and junctions change direction or combine flows between lines. Expandable or accordion conveyors compress for storage and extend to docks or trailers, making them ideal for dynamic shipping areas.
Key advantages include low total cost of ownership – no electrical power, minimal maintenance, and fewer components to service. A gravity conveyor system is easy to configure, extend, or relocate as processes evolve. It also supports safer, more ergonomic handling by reducing manual carrying and letting gravity assist movement. Accessories such as brakes, stops, guardrails, and side guides help control flow and prevent damage.

Choosing the Right Gravity Conveyor

Selecting the right gravity conveyor starts with understanding your loads and operational goals. Consider product dimensions, bottom surface (smooth, ribbed, flexible, or irregular), weight range, and desired throughput. Matching roller diameter, wheel type, axle spacing, and frame capacity to these requirements ensures reliable flow without stalling or excessive speed.
Plan for how products will move, where they must accumulate, and how operators interact with the line. Slope and distance are critical: a slight pitch typically initiates movement for smooth-bottom cartons, while heavier loads or softer packaging may require more slope or closer roller centers to maintain control. If you intend to stage multiple cartons in a lane, confirm frame strength and use line brakes or speed controllers to manage descent on longer declines.
Materials and sizes are widely available to fit different environments. Frames are commonly powder-coated steel for durability or aluminum for lighter, portable applications. Gravity rollers are typically zinc-plated steel for longevity or aluminum to reduce weight and inertia. Standard roller diameters include 1.375 in, 1.9 in, 2.5 in, and 3.5 in; larger diameters support heavier loads and wider packages. Axle centers often range from 1.5 in to 6 in, with tighter centers providing better support for small or flexible items. Common conveyor widths for cartons range from 12 in to 36 in, while pallet applications often use 24 in to 60 in or wider, depending on load size and pallet orientation.
Lay out your facility with attention to elevations, clearances, and traffic patterns. Map origin and destination points, the direction of product flow, and any height changes between work areas. Verify adequate ceiling clearances and keep aisles open for lift trucks and pedestrians. Use curves and spurs to connect pick lines, packing stations, and shipping docks efficiently. Where a natural elevation drop is not available, create pitch with adjustable-height supports. Incorporate protective end stops near docks or pick faces, and plan maintenance access for cleaning and inspections.
Practical selection tips:

• Align roller centers so at least three gravity rollers contact a package at all times to maintain stability.
• Confirm that package bottoms are rigid and flat when using skatewheels; irregular or soft surfaces perform better on a gravity roller conveyor.
• Test a representative sample – both the lightest and heaviest items – to validate slope, speed, and stopping distance before installation is final.
• Balance flow with safety by adding level sections before curves or workstations to reduce momentum.
• Use portable stands and expandable sections if your layout changes frequently or you support seasonal peaks.

Features and Benefits of Gravity Conveyor

Modern gravity conveyor systems are designed for performance, safety, and ease of integration. Typical features include modular frames in straight, curve, and spur sections; multiple roller or skatewheel materials; bolt-together construction for fast installation and reconfiguration; adjustable-height supports; and accessories such as end stops, guardrails, and swing gates for personnel access. Expandable conveyors offer flexibility to extend lines to trailers, docks, or pop-up work cells.
The benefits are substantial:

• Lower operating costs: No energy consumption and simplified upkeep reduce total cost of ownership.
• Minimal maintenance: With fewer moving parts, standard tasks include periodic inspection, cleaning, and replacing worn gravity rollers or wheels.
• Improved throughput: Material moves efficiently, and operators spend less time walking items across the floor.
• Enhanced ergonomics: Reduced lifting and carrying distances help lower strain and support safer work practices.
• Passive accumulation: Gravity flow provides buffering between processes without complex controls.
• Durability: Steel frames and zinc-plated components resist wear and corrosion in typical indoor environments; stainless steel options address washdown or high-humidity areas.
• Easy integration: Gravity sections connect to powered belts or rollers, workstations, carton flow racks, and pallet handling equipment, creating seamless handoffs.

Safety is integral to good design. Guardrails keep products contained, while end stops prevent unintended exits. Speed controllers or retarding rollers manage descent on steeper slopes, reducing impact and product damage. Swing gates and marked walkways support safe personnel access across runs. Lockable supports and floor anchors add stability during use and maintenance.
Performance enhancements such as low-friction bearings, precision-aligned frames, and high-quality fasteners improve consistency and reduce noise. Combined with operator training and clear standard operating procedures, a gravity roller conveyor system can deliver predictable flow that scales as demand changes.

Common Configurations and Specifications

Choosing the right configuration starts with matching roller diameter and spacing to your product mix. Heavier loads and wider packages benefit from larger diameters and higher-capacity frames, while small cartons and polybags need tighter centers for consistent support on a gravity conveyor.

When designing a gravity roller conveyor system, verify that roller gauge, axle type, and bearings meet load and duty cycle requirements. For pallet applications, larger-diameter gravity rollers with reinforced frames prevent deflection and maintain product stability.

Why Choose Gravity Conveyor Solutions

A gravity conveyor offers a high return on investment, especially for facilities focused on reducing energy use, simplifying maintenance, and increasing throughput. A well-designed gravity roller conveyor system can balance slope, spacing, and safety to meet operational objectives. Whether you need fixed lines for order fulfillment, expandable sections for shipping, or integrated gravity and powered segments for complex flows, these solutions scale as demand changes and support efficient, reliable material handling.

Yes, when designed with larger-diameter gravity rollers, higher-capacity frames, and appropriate supports. Align pallet stringers and bottom deckboards with roller centers to avoid sagging, and confirm the frame width suits the pallet orientation in the gravity roller conveyor system.