Accumulating roller conveyors

A basic distinction is made between two systems for stowing goods:

When accumulating with pressure, the conveyed goods come into direct contact with each other or are very close to each other on the conveyor. This leads to pressure between the individual products, the so-called accumulation pressure. At the end of the accumulation section, separation is required to separate the transported goods from each other and ensure a smooth material flow.

The alternative is sectionalized stowage without dynamic pressure. With zero pressure accumulation, the transported goods are positioned at a distance from each other in individual sections. There is no direct contact between the goods on the roller conveyor and therefore no pressure. No additional separation is required at the end of the accumulation section, as the products are already sufficiently separated from each other on the roller conveyor. This type of accumulation is often used in applications where the products are easily damaged or difficult to accumulate, e.g. conical containers or containers with edges that tend to tip over.

Roller conveyors with accumulation systems enable the transport of various goods with different dimensions. Both flat surfaces and goods with a surrounding frame can be transported. These include, for example, workpiece carriers, fridges, dishwashers, brake discs, boxes, washing baskets, steel racks, crates, plastic baskets, batteries and many other goods.

We offer the ideal solution depending on the type of goods to be transported. Our range of idlers includes conveyor rollers with different diameters and lengths with internal friction through to section drives with motorized rollers that enable zero pressure accumulation transport. In addition to accumulation roller conveyors, we offer various roller conveyors such as idle roller conveyors, driven roller conveyors, roller curves, roller conveyors with motorised rollers as well as versatile components for pallet conveyor technology. You can find a selection of our realized projects from belts to rollers and chains here.

Accumulating roller conveyors provide unique benefits over other conveyor types, particularly in applications requiring controlled material flow and temporary buffering. Here’s how they compare:

• Belt Conveyors – Offer continuous movement but lack product separation. Accumulating roller conveyors allow individual product spacing and adjustable accumulation pressure, making them ideal for delicate or irregularly shaped goods.

• Chain Conveyors – Designed for heavy-duty loads, but lack the precision control and flexibility of accumulation systems.

• Traditional Roller Conveyors – Efficient for transporting goods but do not include built-in accumulation functions, potentially leading to congestion and workflow inefficiencies.

• Space & Workflow Optimization – Accumulating roller conveyors provide a compact, efficient, and automation-friendly solution that improves material handling precision and overall workflow efficiency.

• By choosing an accumulating roller conveyor, businesses can enhance automation, reduce material congestion, and ensure a streamlined production process.

Accumulating roller conveyors are designed to control the material flow in conveyor systems in an efficient and controlled manner. They are equipped with rollers that are usually evenly spaced and fitted with a friction drive as required. On rollers with a friction drive, the rotary movement can be stopped while the drive continues to run. A control unit, often in the form of sensors or electronic systems, detects the material flow on the roller conveyor with drive and controls the activation or deactivation of the rollers.

Friction roller conveyors are characterized by a number of special features. Firstly, the rotary motion in these roller conveyors is transmitted by friction, whereby the desired friction force can be individually adjusted during operation. Secondly, the conveyed goods touch each other during accumulation on the roller conveyor. This means that the more conveyed goods are accumulated, the greater the accumulation pressure on the first accumulated conveyed goods. For individual transport following the accumulation, the conveyed goods must be separated using suitable devices on the roller conveyor.

An accumulating roller conveyor is used to link several processing machines that are responsible for individual work processes. This system enables heavy weights and loads to be transported with ease. Our friction roller conveyors allow you to precisely control the material flow. With our conveyor technology, you can ensure smooth and efficient material movement in complex conveyor systems.

Systems with accumulation rollers are widely used in conveyor technology and are particularly suitable for situations in which a temporary delay or a temporary standstill of conveyed goods is required. The areas of application for powered roller conveyors with accumulation systems include processing stations, buffer zones, quality control, material handling and assembly areas.

We have realized various projects with accumulating roller conveyors for our customers. Among other things, we have planned and implemented a conveyor system for transporting and positioning different brake drums to a handling unit. The brake drums are transferred from a customer roller conveyor to the new accumulation roller conveyors. Using stop components and separators, the incoming brake drums are separated and conveyed separately to the centering unit.

Another project from our portfolio is the transport of empty small load carriers (KLTs) to a filling station. The accumulation roller conveyor is equipped with an infeed at the start, which makes it easier to insert the KLTs.

One of the key advantages of accumulating roller conveyors is their high degree of customization, allowing them to be tailored for industry-specific applications. In automotive manufacturing, these systems efficiently handle brake discs, gear components, and engine parts, ensuring precise sequencing and staging for assembly. In the food and beverage industry, accumulation conveyors can be designed with stainless steel rollers and non-stick coatings to meet hygiene standards while handling packaged goods or raw ingredients. Similarly, in pharmaceuticals and electronics, friction-controlled accumulation ensures that fragile items such as medicine bottles, circuit boards, and medical devices are transported without damage. Custom features like variable roller spacing, motorized zones, and integrated stop mechanisms further enhance the adaptability of these conveyors, allowing companies to optimize their workflow and minimize handling risks.

Modern accumulating roller conveyors are enhanced with advanced automation technologies, offering businesses improved efficiency, accuracy, and cost savings. Key automation features include:

• Sensor-Based Controls – Detect product movement, regulate spacing, and prevent collisions for seamless material flow.

• Programmable Logic Controllers (PLCs) – Enable real-time tracking, adaptive speed adjustments, and automated workflow synchronization.

• IoT-Enabled Monitoring – Provides remote access to conveyor performance data, predictive maintenance alerts, and operational insights.

• Zero-Pressure Accumulation (ZPA) Systems – Utilize motorized roller sections to maintain proper spacing between products, preventing damage and bottlenecks.

• Integration with Robotics & WMS – Seamlessly connects with robotic arms, pick-and-place systems, and warehouse management software (WMS) for full automation.

• Energy-Efficient Operation – Smart roller activation reduces power consumption by only running sections when needed.
  
  

By incorporating these automation solutions, businesses enhance efficiency, reduce downtime, and optimize material handling processes, making accumulating roller conveyors a smart and scalable investment.

At TEGEL-TECHNIK, we combine our expertise in hardware and software construction to develop customized accumulating roller conveyor solutions tailored to your specific needs. Our precision-engineered systems ensure seamless material flow, optimized automation, and maximum efficiency. Get in touch with us today to discuss your individual requirements and discover how our innovative conveyor technology can enhance your operations.