Affordable Conveyor Upgrades: Small Solutions That Deliver Big on Efficiency

December 04, 2024

Finding ways to improve efficiency without breaking the budget is always top of mind in consumer packaged goods. One of the most effective yet often overlooked solutions is upgrading your conveyor systems. Small, strategic improvements to your conveyors can yield significant efficiency gains. From optimizing flow to reducing downtime, upgrades are a smart investment that can transform operations and deliver a high return, all without draining your resources.

Here are four affordable upgrade ideas that are relatively easy to implement:

1. Add electrical controls.  We can add electrical controls to a production line to remedy a number of efficiency challenges. For instance, many types of ongoing jamming issues can be solved with the addition of sensors. Or, when inconsistent product flow is constantly bringing your equipment to a stop, speed modulation with sensors like photos eyes, limit switches and proximity sensors could be the answer for increasing line efficiency.

If you have some of these issues, schedule a visit by our experts. They can audit your line to determine if controls could make an improvement. Our team of electrical and mechanical engineers understands how to design conveyor controls and integrate them with existing systems­—it’s what they do every day!

2. Simplify changeovers with a Rapid-Rail® for your existing Nercon equipment. This is real efficiency innovation for lines with frequent product changes. The Rapid-Rail makes it possible to quickly adjust the entire line, manually or electronically, from just a few locations. It can be used with straight or curved conveyors, and can be retrofitted on your current Nercon conveyors. Watch our demo videos to see how the manual and electronic adjustment works.

3. Add buffering with an accumulation solution. Buffering optimizes production efficiency by allowing operations to continue even when downstream production is temporarily halted. We offer several options in accumulation equipment:

• Nercon’s rotary accumulation table can be used at different points on the production line or for end-of-line needs. Our 48” table can be delivered to your facility in 10 days.
• Our bi-directional accumulation table uses sensors to start accumulation as needed. When production is clear, the bi-di table automatically pushes product back onto the production line, matching down-line equipment surge rate.
• Our re-flow accumulation conveyor is configurable for a variety of product sizes and materials, and has a small footprint for maximum versatility.

See all of our conveyor accumulation solutions.

4. Save time and increase throughput with a hand pack station. Our hand pack stations boost production efficiency on packaging lines by streamlining labor-intensive tasks. With a steady, controlled flow of product, packers can quickly pick and place items into containers, eliminating product backups. The stations reduce safety concerns and eliminate the need to leave the area.

Want to speak with one of our conveyor experts or schedule a visit to review your line? Give us a call at 844-293-2814 or request a callback.