Roller conveyors with motorized rollers

The roller conveyors can transport a variety of goods with a flat surface or surrounding base frame in variable widths. These include pallets, workpiece carriers, fridges, dishwashers, brake discs, cardboard boxes, washing baskets, crates and baskets.

In addition to roller conveyors with motorized rollers, we offer various conveyor systems with roller conveyors that can be used depending on the intended purpose. These include idle roller conveyors, driven roller conveyors, accumulating roller conveyors, gravity roller conveyors and Pallet roller conveyors in our product range. Convince yourself of our wide range of expertise in roller conveyors, drives and plant engineering: You can find a selection of our realized projects here.

Powered roller conveyors with motorized rollers are a special type of roller conveyor that enables goods to be transported over inclines, declines and horizontal distances. They are characterized by their compact design as, unlike conventional roller conveyors, the drive is integrated into the rollers. The drive segment usually consists of a motorized roller, which transmits its rotary motion to several rollers without its own motor via a belt or chain. The roller conveyor consists of several drive segments that move the conveyed goods along.

The rollers of the roller conveyor are made of different materials, such as steel or plastic, depending on the application and load capacity. The size and number of rollers depend on the size and weight of the goods to be transported. The power of the motor must be adapted to the conveying speed, the length of the roller conveyor and the weight of the goods. One advantage when used as a buffer conveyor is the accumulation of the conveyed goods in the individual segments without back pressure.

The frame forms the basis of the roller conveyor and supports all other components of the system. It is usually made of robust steel or aluminum to withstand the expected load. The length and shape of the frame depend on the desired length and layout of the roller conveyor.

The control of the driven roller conveyors regulates both the speed and the direction of rotation of the motorized rollers and can be carried out manually via a PLC (programmable logic controller) or via a bus system. Sensors are connected to the conveyor control system to detect the position of the goods and control their onward transport.

Powered roller conveyors offer distinct advantages compared to other material handling solutions, particularly in applications requiring controlled movement, accumulation, and automation. Unlike traditional conveyor systems, powered roller conveyors provide individualized transport control, improving efficiency, flexibility, and energy consumption.

• Belt Conveyors – While belt conveyors provide continuous transport, powered roller conveyors offer modular movement, better control over product positioning, and zero-pressure accumulation, making them ideal for fragile or irregularly shaped goods.

• Chain Conveyors – Chain conveyors are better suited for heavy-duty applications, but they lack the precision and energy efficiency of powered roller conveyors, which can stop, buffer, or accelerate goods with minimal mechanical wear.

• Gravity Roller Conveyors – Gravity conveyors rely on slopes and manual force, while powered roller conveyors ensure consistent movement, speed control, and automated sorting, reducing manual labor and improving throughput.

• Accumulating Roller Conveyors – Accumulating roller conveyors allow for temporary storage, but powered versions with motorized rollers provide precise zoning and intelligent accumulation control, reducing product congestion and improving process flow.

Roller conveyors with motorized rollers are an indispensable aid in modern logistics. They enable the efficient and reliable transport of goods and merchandise in a wide variety of industries. They can be found in: 

• Production plants: In production plants, roller conveyors with motorized rollers are often used to transport raw materials, semifinished and finished products from one station to the next. They can also be used for storing and buffering products.

• Warehouses: In warehouses, roller conveyors with motorized rollers are often used to transport goods from goods receipt to the warehouse and from the warehouse to dispatch, sorting and picking goods.

• Shipping: Roller conveyors with motorized rollers play an important role in shipping. They transport goods to packing stations and loading ramps, sort goods by destination or shipping method and support the palletizing and depalletizing of goods.

• Logistics centers: In logistics centers, roller conveyors with motorized rollers support the sorting and distribution of goods, buffer goods before shipping and efficiently load and unload trucks.

• Automotive industry: In the automotive industry, roller conveyors with motorized rollers are used in the assembly and production of vehicles. They transport parts and components between production stations, buffer parts before and after assembly and ensure smooth production.

One of the biggest advantages of powered roller conveyors is their customizability, allowing businesses to tailor their conveyor systems to their specific industry requirements. Different industries require specialized features to ensure efficiency, compliance, and adaptability.

• Retail & E-commerce – High-speed transport and sorting of packages with barcode scanning and integration into warehouse management systems (WMS).

• Pharmaceutical & Food Industry – Hygienic conveyor designs with stainless steel rollers, anti-microbial coatings, and washable components to meet sanitation regulations.

• Automotive & Heavy Industry – Heavy-duty rollers designed for large and heavy components, including custom coatings for delicate parts.

• Manufacturing & Production – Seamless integration into robotic workstations, buffer storage zones, and quality control checkpoints.

• Logistics & Distribution – Multi-level conveyor integration with automatic sortation and accumulation zones, ensuring smooth and uninterrupted material flow.

Modern powered roller conveyors can be fully integrated into automated logistics and production environments, providing smart control, data-driven insights, and energy-efficient operation.

• IoT & Smart Sensors – Real-time monitoring of roller status, product movement, and predictive maintenance alerts to minimize downtime.

• Programmable Logic Controllers (PLCs) – Seamless coordination between conveyor segments, adjusting speed, stopping zones, and accumulation functions based on production demands.

• Zoned Control for Energy Efficiency – Intelligent zoning systems activate only necessary sections of the conveyor, reducing power consumption and wear.

• Integration with Warehouse & ERP Systems – Direct communication with inventory management, ensuring automated sorting, tracking, and handling of goods.
  
  

At TEGEL-TECHNIK, our expertise extends beyond mechanical engineering—we provide comprehensive hardware and software solutions to ensure seamless integration, precise control, and maximum efficiency in your conveyor systems. From intelligent automation to customized control units, we deliver state-of-the-art technology tailored to your operational needs.

No matter the industry or specific conveyor requirements, TEGEL-TECHNIK brings decades of expertise in designing and manufacturing customized conveyor solutions tailored to your needs. Get in touch with us today to develop a highly efficient, industry-specific conveyor system that enhances your operations and maximizes productivity.