Different Types of Conveyors and Their Uses

Walk into any modern factory, from a biscuit plant to a tablet packaging unit and you’ll see one thing in constant motion: conveyors. They’re the unsung heroes of automation, quietly moving products from one stage to another, ensuring every process flows smoothly and efficiently.

But not all conveyors are the same. Depending on the product, environment, and space available, industries rely on different types of conveyors to meet their unique needs. Some are designed for hygiene and precision, others for speed and heavy lifting.

Let’s understand the main conveyor types, their real-world applications, and how Nexgen Machines designs systems that make production faster, cleaner, and smarter.

Conveyor systems are mechanical setups that move materials from one point to another, safely, efficiently, and with minimal human effort. They form the backbone of automated production, helping factories achieve consistency, hygiene, and continuous flow.

In industries like food processing, pharmaceuticals, and packaging, conveyors do more than transport items; they maintain sanitary conditions, reduce manual handling, and increase output.

At Nexgen Machines, every conveyor is engineered to fit its environment perfectly. From Z Conveyors for vertical transfers to Inspection and Sorting Conveyors for quality assurance, each system is built with a purpose, efficiency, hygiene, and space optimization.

1. Belt Conveyors
The most common type, belt conveyors use a continuous belt loop powered by pulleys to move materials along a set path. They’re ideal for transporting lightweight items like packaged foods, bottles, or pharmaceutical trays.

The belt surface can be customized flat, cleated, or modular, depending on the product type. In hygiene-sensitive industries, Nexgen uses stainless-steel frames and food-grade belts to maintain cleanliness and prevent contamination.

Where you’ll see them: Snack factories, tablet packaging lines, or bakery units where gentle yet consistent movement is essential.

2. Roller Conveyors
For heavier loads like cartons, crates, or machinery components, roller conveyors are the go-to choice. They consist of multiple rollers that rotate, allowing items to move either manually (gravity-based) or automatically (motor-driven).

Powered roller conveyors use motors for controlled movement, while gravity conveyors rely on slope and momentum, perfect for assembly lines or warehouse dispatch sections.

Nexgen designs both types, ensuring smooth transfer without product damage or backlogs.

Common use cases: Automotive assembly lines, logistics centres, and packaging plants.

3. Z Conveyors
A standout in modern factories, Z Conveyors are engineered for vertical movement. Their unique “Z-shaped” design allows materials to move between different height levels, for example, lifting products from ground-level processing to upper-level packaging.

By reducing the footprint of long horizontal conveyors, Z Conveyors save valuable floor space, a big advantage in compact facilities.

Nexgen’s Z Conveyor systems come with customizable belt widths, inclines, and discharge angles to suit diverse materials from food items to granules or small mechanical parts.

Example: In a snack plant, Z Conveyors carry chips from the fryer to the seasoning drum or packaging area fast, hygienic, and without spillage.

4. Inspection and Sorting Conveyors
In industries where quality control is critical, Inspection and Sorting Conveyors play a vital role. These systems help identify and remove defective or contaminated products before they reach packaging.

They can be integrated with cameras, sensors, or manual inspection points, allowing operators to detect color variations, foreign particles, or weight differences.

Nexgen builds inspection conveyors with adjustable speeds, ergonomic working heights, and easy-to-clean structures, ensuring hygiene and operator comfort go hand in hand.

Typical use: Food sorting lines, pharmaceutical bottle inspection, and packaging quality checks.

5. 2-Tier or 3-Tier Conveyors
When floor space is limited, multi-tier conveyors, either 2-tier or 3-tier, offer a smart alternative. These systems operate on multiple levels, allowing simultaneous operations such as sorting on one tier and packaging on another.

They’re especially useful in compact production environments or where parallel processes run side-by-side.

Nexgen’s multi-tier designs are engineered with precision alignment and safety in mind, ensuring stable performance even during continuous, high-volume operations.

Example: A chocolate plant using a 2-tier conveyor, the top layer cools finished bars while the lower one moves wrapped products to the boxing station.

6. Specialized Conveyor Designs
Not every process fits a standard design. That’s why Nexgen also builds specialized conveyors such as modular, chain, or slat conveyors, tailored for unique materials or challenging conditions.

• Modular conveyors: For flexible assembly lines that require frequent layout changes.
• Chain conveyors: For heavy-duty applications like metal parts or industrial drums.
• Slat conveyors: Ideal for heat-resistant or bulky materials.

Each of these designs can be integrated into existing automation systems, ensuring maximum productivity with minimal downtime.

Every industry has distinct needs, and conveyors adapt to them seamlessly:

Food Industry

• Z Conveyors for lifting washed produce or snack items.
• Inspection Conveyors for removing damaged or misaligned products.
• Stainless-steel belt conveyors for hygienic transport of packed goods.

Pharma Manufacturing

• Inspection and Sorting Conveyors for tablet or vial checking.
• Cleanroom-grade belt conveyors for sterile material transfer.

Automotive and Engineering

• Roller conveyors for heavy parts like bearings or engine components.
  Chain conveyors for assembly or finishing sections.

Packaging Units

• 2-tier or 3-tier conveyors for multi-stage sorting, labeling, and packing in compact spaces.

Across all these applications, Nexgen’s conveyor systems combine hygiene, efficiency, and intelligent engineering ensuring reliable performance in demanding environments.

Selecting the right conveyor isn’t just about moving products; it’s about optimizing workflow, space, and output. Here’s what to consider:

Conveyors are more than moving belts or rollers; they’re the foundation of industrial automation. Understanding the different types of conveyors helps businesses plan better layouts, improve safety, and maintain continuous production without bottlenecks.

With years of experience designing solutions for food, pharma, and manufacturing sectors, Nexgen Machines continues to deliver conveyors that combine performance with hygiene and durability.