Carton and Box Conveyor Systems
The product
Automating the movement of boxes and lightweight loads in the warehouse
A carton conveyor is a continuous, automated transport solution for boxes and light loads. It can consist of roller, belt or toothed belt modules. The wide range of box conveyor variants and multiple combination options allow for the design of simple or complex solutions tailored to each company’s needs.
Carton conveying systems minimise manual goods handling as well as operator and equipment traffic, boosting productivity while reducing errors and operating costs.
Advantages of box conveyor systems
- Long distances: extensive, complex circuits can be designed to connect the different areas of a facility.
- Constant flow: carton conveyors move goods continuously.
- Multiple unit loads: these systems are compatible with cartons, boxes, trays, totes, bins, cases and crates of various materials and sizes, in addition to other lightweight loads.
- Flexibility and scalability: box conveyors allow for the creation of any type of circuit, while existing systems can be expanded or modified.
- Ergonomic operation: staff perform tasks such as order fulfilment more comfortably with carton handling systems.
- Robust construction: case conveyors are a durable solution for high-performance operations.
- Minimal maintenance: their upkeep is simple and cost-effective.
By using carton conveyors, we’ve ramped up our productivity. Our processes are much faster and more reliable
Carton conveyor applications
Highly effective solution adaptable to a wide variety of needs
Box roller conveyors are the perfect solution for automating the movement of cartons and light loads in warehouses with repetitive, constant flows. Thanks to their high versatility, they seamlessly adapt to various operations and accommodate multiple system configurations with varying degrees of complexity.
Connection between warehouse zones
A core function of carton conveyors is moving unit loads between a point of origin and a point of destination, linking different areas of a facility.
AS/RS unit load movements
Box conveyors are essential at the front, infeed and outfeed points and pick stations of miniload automated storage and retrieval systems (AS/RSs).
Facilities with intensive picking
Tote conveyor systems speed up order fulfilment by facilitating goods handling and connecting pick stations with consolidation and dispatch areas.
Automated order sorting
By installing case conveyor systems in dispatch zones, companies can set up sorters to classify goods based on several criteria, (e.g. by order or route).
Goods receipt and distribution
Tote conveyors automate the receipt of boxed goods and their distribution to designated locations.
Assembly and inspection stations
In production centres, conveyors transport components to workstations on assembly lines. They also streamline the flow of finished products to quality control checkpoints.
Testimonials
The carton conveyor allows us to gain efficiency following the packaging phase. Once the orders leave the conveyor, they’re ready to be shipped.
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Thanks to automation in the form of the pallet and carton conveyors and elevators, flows are now much quicker, and we’ve significantly reduced operator movements.
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One challenge was how to move goods between different floors. To solve it, Mecalux installed a box conveyor and elevator to connect all the building levels and speed up goods transfers.
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Case studies
Normagrup: automation shines a light on logistics
Normagrup, a leading Spanish company in the emergency lighting market, has added on to its production plant in Asturias, Spain, with an AS/RS for boxes. Managed by the Easy WMS warehouse management system from Mecalux, this AS/RS houses all the components used to manufacture Normagrup's products. Read more
The high throughput of the automated warehouse for boxes at JCH
JCH, a leading air conditioning company, improves the storage and picking capacity of its components warehouse in Barcelona. Read more
General Óptica installs an omnichannel warehouse with 4,000 daily orders
General Óptica, a leading Spanish retailer of prescription glasses, sunglasses, contact lenses and hearing aids, has opened a logistics centre in Madrid. The warehouse, equipped with box conveyors, pallet racking and picking shelves, fulfils 4,000 orders a day and manages 100,000 SKUs. Read more
Picking shelves with walkways and a complete conveyor circuit boost e-commerce sales of a spare parts distributor to the automotive sector
Case study of the Automotive Parts Factory picking warehouse in France developed by Mecalux and other examples of storage systems. Read more
C.D.A.L. Automatic transport between warehouse and dispatch
The spare car parts company C.D.A.L. has implemented a Mecalux conveyor circuit in its distribution centre in Saint Priest (France), which automatically connects the warehouse with the dispatch area. The conveyors provide very fast movement of goods. Read more
Conveyor belts as the axis of a picking facility distributed over several floors
PAVI, a major supplier of auto spare parts from France, hired Mecalux to install the necessary equipment in its warehouse in Saint-Priest, a town near the city of Lyon. The supply included two levels of mezzanines, racking, conveyor belts and automatic sorters, as well as the Mecalux Easy WMS warehouse management system. Read more
A full conveyor circuit multiplies the picking productivity of DYI goods manufacturer Vynex
Case study of the Vynex picking warehouse in France developed by Mecalux and other examples of storage systems. Read more
CCV: automatic conveyors for managing 20,000 products a day
Fashion retailer CCV has opened a warehouse in north-east France to tackle the challenges posed by omnichannel retail. Mecalux has installed a conveyor system for boxes that has raised the internal goods flow by 66% compared to CCV's previous warehouse. Read more
Types of carton conveyors
Mecalux’s wide range of box conveyor solutions supports multiple distance, path, incline, speed and unit load requirements. The systems’ robust design ensures high reliability in all work environments.
A carton handling system can include both roller and belt conveyors. These machines streamline the movement and handling of boxes, trays, cases and other lightweight loads in warehouses. Standard conveying speeds range from 25 to 60 m/min.
Auxiliary conveyor equipment adapts the circuit layout to meet each facility’s specific needs. These devices help bypass structural obstacles, change the unit loads’ travel direction or create diverging paths.
Zero-pressure accumulation roller conveyor (LRA)
Moves boxes in a straight line without contact between them. It can also perform accumulation functions. Each section of this carton accumulation conveyor is equipped with its own motorised roller, allowing for independent operation.
Continuous powered roller conveyor (LRC)
Transports cartons in a straight line, allowing them to accumulate in contact with each other. This conveyor type is ideal for long distances, even with slight inclines. Unlike the LRA, it operates with a single motor that provides enough traction to maintain a continuous flow.
Continuous belt conveyor (LBC)
Functions similarly to the LRC but replaces rollers with a continuous belt. The increased adhesion between the belt and unit loads allows its use on both horizontal and inclined sections (up to 24°). The LBC is powered by a single motor.
Free roller conveyor (LRL)
System with non-motorised rollers, suitable for gravity-flow accumulation channels, dispatch areas and pick stations. It supports an incline of 4% to 8%.
Elevators
Lift and lower boxes to connect different floors or conveyor levels. A box elevator conveyor can be continuous or discontinuous.
Curved accumulation conveyor (LRAC)
Designed to create non-linear flows or circumvent architectural barriers (e.g. columns). It allows for direction changes at various angles (30°, 45°, 60°, 90° and 180°) and can be combined with other conveyor elements. It operates similarly to the LRA: it allows accumulation, and each section operates independently with a motorised roller.
Launcher conveyor (LTR)
Changes direction by 90° a junction, launching loads perpendicularly via a motorised roller. Its function is to introduce boxes into a moving circuit. This device offers great flexibility in receiving and dispatch operations.
Pusher conveyor (LTE)
Changes the direction of the load within a conveyor system at any given moment, facilitating the flow of goods and optimising cycle time. The LTE is equipped with a blade on the side that pushes boxes perpendicularly.
Cross transfer roller & toothed belt conveyor (LTM)
Enables direction and orientation changes of 90° and 270° relative to the entry direction. The LTM provides high-performance solutions in crossing areas. It combines a fixed roller conveyor and an orthogonally positioned toothed-belt conveyor with a lifting mechanism.
Diverter conveyor (LRD)
Facilitates high-speed directional changes. The LRD is ideal for systems transporting large quantities of unit loads with diversions to secondary lines. It can be configured for 30° and 45° detours.
Merge roller conveyor (LRI)
Allows high-speed directional changes in circuits requiring induction toward a main conveyor line. Diversions can be made at 30° and 45°.
Lift-hold conveyor (LEE)
Designed for load pick-up and delivery via stacker cranes at the entry and exit points of an AS/RS with a conveyor system positioned at the front. The LEE combines a roller conveyor with a lifting device. It is available in two configurations: single-load and double-load.
Toothed-belt conveyor for boxes (LCF)
Collects and delivers loads through stacker cranes at the entry and exit points of an AS/RS with a conveyor system set up on the side.
Conveyor gate
Structure with a gate that can be raised vertically to create an opening for operators and handling equipment to pass through the conveyor system.
Carton conveyor accessories
Complementary solutions that improve conveyor system safety and capabilities
Checkpoint
Designated station for inspecting unit load dimensions (gantry gauge) and/or identifying labels via scanner.
Scale
Device used to check weight at entry points, pick stations or sections of the conveyor system transporting orders ready for dispatch.
Crossover
Structure consisting of two staircases and an elevated walkway to allow safe, convenient passage through the system without disrupting conveyor operation.
Safety enclosures
Metal mesh fencing that delimits the conveyor system to prevent operators from coming into contact with moving parts that could pose risks.
FAQs
A box or carton conveyor is a continuous handling system that automates the internal flow of boxes, totes, crates, bins, trays and other light loads. Commonly used in warehouses and production centres across various industries, conveying systems streamline multiple operations, from goods receipt to order fulfilment and dispatch.
Case conveyor systems can transport a wide range of goods stored in boxes, trays and other unit loads of various materials and sizes. They can also handle loose items, packages and even tyres.
Mecalux offers several varieties of carton handling systems, including roller, belt, and mixed roller/toothed belt box transfer conveyors. With box roller conveyors, unit loads are driven by a set of metal cylinders rotating on a shaft and powered by a motor or gravity. In contrast, belt conveyors move boxes and other small unit loads along a continuous surface made of rubber or plastic, which rotates between two motorised drums at the ends of the structure. Finally, mixed conveyors — cross transfer units combining rollers and belts arranged at 90° angles — change the direction or orientation of transported unit loads.
The height of a standard carton conveyor is adjustable, ranging from 570 to 750 mm in horizontal sections and reaching up to 3,000 mm high in inclined segments. The maximum usable width varies by conveyor model but is typically between 400 and 800 mm.
Box and case conveyor systems can handle small unit loads weighing up to 100 kg.
The speed of a box conveyor depends on the characteristics of the unit load transported and ranges from 25 to 60 m/min.
Thanks to Mecalux’s wide range of conveyors, any type of layout can be designed, from simple straight-line systems with one point of origin and one destination to complex circuits with multiple entry and exit points. This versatility ensures the system adapts to specific operational needs. Curved conveyors, for example, help navigate architectural obstacles, while cross transfer conveyors change the direction and orientation of unit loads.
Yes, conveyor lines can link various levels via box conveyor belts as well as continuous or discontinuous box elevator conveyors.
Carton conveyor systems are flexible, scalable solutions that can be adapted to warehouse requirements at any given time. This means the circuit can be expanded or the route changed as needed.
Yes. Any conveyor solution requires a warehouse control system (WCS) to govern its operation. The WCS instructs the conveyors to move, stop or turn unit loads based on pre-parametrised logical sequences that consider the route, number of conveyors and other circuit elements. The WCS should not be confused with a warehouse management system (WMS), which functions at a higher level. More complex circuits require both a WCS and a powerful WMS — such as Mecalux’s Easy WMS — to direct unit loads from origin to destination according to each facility’s specific criteria (order, sequencing, etc.).
Yes, there are two solutions for this. One option is to install conveyor crossovers that enable personnel to walk over the system. The other is to integrate sections with conveyor gates that can be lifted to one side, creating ground-level passageways. This second solution is recommended if handling equipment needs to pass through the conveyor lines.
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