Belt or roller conveyors: which system suits your products best?

THE DYNO ADVANTAGE

Belt or roller conveyors: which system suits your products best?

Reading time: 4 minutes

If you are short on time, here is the essential guide to choosing the right system for your operation.

Choose Belt Conveyors if you handle loose, irregular, or fragile items (like bags or bulk materials) or need to move products up steep inclines (up to 30°).
Choose Roller Conveyors if you move rigid, flat-bottomed items (like boxes or pallets) and need to accumulate or “buffer” products without stopping the motor.

Other key differences

Elevation: Belts handle steep slopes well / Rollers are usually best for horizontal runs.
Maintenance: Belts require regular checks / Rollers offer easier, individual part replacement and very low maintenance for the DynoDrive range in particular.
Efficiency: Roller systems are often highly energy-efficient (gravity or low-voltage motors).

Belt conveyors: versatile systems for irregular loads and level changes

The Tranzbelt S20 series conveyors, with their robust design and precision-engineered drive system, are especially suitable for ensuring smooth transport of varied and irregular products whilst maintaining a consistent rate. Belt conveyors facilitate continuous movement of goods, particularly in settings requiring smooth and uninterrupted transport. These systems rely on a powered belt to carry various types of products across your facility, from small loose items to bulk materials.

Advantages

Versatility: Appropriate for products of all shapes and sizes, including irregular, fragile or bulk items. The Tranzbelt’s anti-static properties make it suitable even for electronic components. Belt conveyors can handle liquids in bags, powders, loose bulk products, cardboard boxes and plastic crates with equal ease.
Continuous transport: Ideal for long distances and automated processes, with the S20 series capable of maintaining consistent speeds up to 40 metres per minute.
Adaptability: Perfectly suited for inclines or declines, level changes and variable speeds. Dyno’s customisable systems can accommodate gradients up to 30° with special cleated belts. Troughed versions are available for loose products where side containment is required.
Use in multiple sectors: Food processing, pharmaceutical, e-commerce and more. The food-grade silicone belts available with the Tranzbelt series comply with all relevant hygiene regulations.
Custom specifications: Able to be specified ‘fit-for-purpose’ to ensure optimal performance in its application.
Long life: Ply belts offer excellent durability when properly maintained, providing years of reliable service.

Disadvantages

Maintenance costs: The belt needs regular maintenance and replacement if it wears out, though Dyno’s reinforced belts offer industry-leading durability.
Sensitivity to dirt: Build-up of debris can affect operation and requires frequent cleaning, particularly in dusty environments.
Limited accumulation: Belt conveyors have restricted capabilities for accumulation, stops and transfers compared to roller systems.

Roller conveyors: efficient solutions for accumulation and modular layouts

A roller conveyor operates using a series of rollers that move loads either by gravity (gravity conveyor) or via a powered system. The Tranzband and DynoDrive series powered conveyors, with their 50mm diameter rollers, are ideal for handling all types of loads. Roller conveyors represent a proven solution for many applications. For pallets, Dyno offers line shaft models with capacities up to 300kg, whilst pallet conveyors can handle loads up to 2,000kg.

Powered roller conveyors come in several drive configurations. DynoDrive systems are the most economical and flexible, perfect for boxes and crates. Chain-driven rollers excel in heavy-duty applications and extreme environments. Belt-driven systems offer the latest technology with exceptional power savings, flexibility and control possibilities.

Advantages

Ideal for rigid and flat loads: Perfectly suited for crates, cartons, pallets and other items with a flat base. Roller pitch can be changed to ensure smooth transport even for smaller packages.
Less maintenance: No belt to replace, and rollers can be changed individually if needed. The sealed bearings in Dyno’s systems require minimal lubrication.
Energy efficiency: The Ezroll gravity model does not require any power source, thus reducing operating costs, whilst the DynoDrive uses efficient 24V DC motors that minimise energy consumption. Belt-driven roller systems offer significant power savings over traditional drives.
Modularity: Easy to adjust and reconfigure according to needs, with the possibility of creating complex circuits with curves, diverts, gates, etc.
Safety and quiet operation: DynoDrive systems offer excellent safety features and operate quietly with minimal noise compared to chain-driven alternatives.
Accumulation capability: Roller systems can accumulate products without damage, making them ideal for flexible manufacturing and dispatch operations.

Disadvantages

Less suited to fragile or irregular items: Risk of imbalance for light or unstable products, though the adjustable speed controls can mitigate this issue.
Requires a flat base: Not suitable for bulk products or irregular surfaces unless used with appropriate containers.
Speed and incline limitations: Line shaft systems have speed restrictions and cannot handle inclines, though belt-driven rollers offer greater flexibility in this regard.

Comparison of the two systems

Understanding the differences between these systems helps ensure you select the right solution for your operation. The table below provides a quick reference guide:

Criterion	Belt Conveyors	Roller Conveyors
Best for product types	Irregular shapes, bulk materials, bags, small items, fragile products	Boxes, crates, pallets, items with flat rigid bases
Elevation capability	Excellent – inclines and declines up to 30°	Limited – horizontal or slight decline (gravity), horizontal only (line shaft powered)
Maintenance requirements	Regular belt inspection and periodic replacement	Lower – individual roller replacement as needed
Energy efficiency	Continuous power required for movement	Excellent – gravity requires no power; powered options use efficient 24V motors
Accumulation capability	Limited	Excellent – can accumulate without product damage
System flexibility	Good for straight runs and curves, excellent for elevation	Excellent – easy to reconfigure with curves, diverts, gates, merges, sortation
Initial cost	Economical for most applications	Very low (gravity) to moderate (powered)
Environmental suitability	Can be specified with food-grade, anti-static, or hygiene-compliant materials	Chain-driven handles extreme temperatures, options for hygiene-critical applications

In a nutshell

Belt conveyors excel where product variety is high and where elevation changes are required. Their continuous surface supports products of any shape, making them ideal for facilities handling diverse goods.

Roller conveyors shine in applications with standardised packaging and where accumulation or complex routing is needed. The ability to modify individual sections without replacing entire systems makes them particularly cost-effective for growing operations.

How to choose the right conveyor for your needs?

Dyno’s solutions are fit-for-purpose, cover a wide range of needs, from lightweight packages to heavy pallets. The choice between a belt conveyor and a roller conveyor depends primarily on several key factors:

Product characteristics: Consider size, weight, base stability and surface type. Products with irregular shapes, flexible bases or bulk materials suit belt systems. Rigid items with flat bases work well on rollers.
Environment: Temperature extremes, hygiene requirements and cleaning procedures influence system selection. Belt systems can be specified with food-grade materials, whilst certain roller types handle extreme temperatures better.
Layout requirements: Vertical movement, curves and complex routing affect your choice. Belt conveyors handle inclines and declines naturally, whilst roller systems offer excellent flexibility for horizontal routing with curves and diverts.
Budget considerations: Initial investment, operating costs and maintenance expenses vary between systems. Gravity roller conveyors offer the lowest cost option where applicable, whilst powered systems require evaluation of long-term operating expenses.

And obviously, some systems require the utilisation of both belt and roller conveyors combined!

The selection of a conveyor ultimately depends on your business and the characteristics of your products. Dyno offers appropriate solutions, whether belt conveyors (Tranzbelt series) or roller conveyors (Tranzband, DynoDrive and Ezroll series). Our engineering team can also create custom systems to meet specific requirements, including hybrid solutions that incorporate both technologies where appropriate.

Belt or roller conveyors: which system suits your products best?