Bottomless Conveyors: Applications, Benefits and Leading Manufacturers

Introduction to Bottomless Conveyors

Conveyor systems are integral components of many manufacturing, warehousing, and logistics operations. They efficiently move products and materials between processes, reducing labor requirements and increasing productivity. Traditional conveyors feature a belt with defined sides that prevents items from falling off. However, some specialized applications utilize bottomless conveyors that lack these boundaries.

What Are Bottomless Conveyors?

Bottomless conveyors are systems designed without side walls along the belt. This allows products to be moved on and off the conveyor from any point of the production line, rather than at just the end point. It provides greater flexibility in material handling automation.

These conveyors are also referred to as edgeless conveyors or open-type conveyors. They utilize a flat belt or modular plastic belt that loops around the system without exterior confines. The lack of walls allows for easy integration with other equipment, workstations, or processes.

Types of Bottomless Conveyor Systems

There are a few common types of bottomless conveyors used in industry:

• Belt conveyors - Feature a flat rubber or PVC belt without edges
• Modular plastic belt conveyors - Constructed from interlocking plastic modules that create a wide mesh-like belt surface
• Chain edge conveyors - Uses specialized chains without side guides
• Wheel conveyors - Wheels embedded into the belt eliminate need for return rollers/slides

The choice depends on the weight and dimensions of materials being transported. Heavier items may require modular plastic belts or wheel conveyors capable of handling more substantial loads. Customization for specific purposes is also common.

Benefits of Bottomless Conveyor Systems

There are several advantages associated with bottomless conveyors:

• Better integration - Products can be loaded or unloaded from any point rather than just the end.
• Increased flexibility - Allows flowing movement on and off the line from multiple workstations.
• Improved efficiency - Workers or robotic automation can access materials faster.
• More options - Provides greater versatility in production line configuration through modular design.
• Cost-effective - Eliminates need for expensive traditional conveyor housing and guides.

Applications of Bottomless Conveyors

Bottomless conveyors have many uses across industrial sectors:

• Food production lines - Allows adding ingredients or components from multiple points.
• Packaging facilities - Items can be packed, sealed, labeled appropriately as they move through.
• Order fulfillment - Provides access to products for piece-picking or order assembly from any location.
• Parts manufacturing - Streamlines processes requiring incremental construction or alterations.
• Warehousing - Improves material flows for receiving, put-away, order-picking and shipping operations.

Considerations When Implementing Bottomless Conveyors

While this style of conveyor offers advantages, some key points should be considered before installing in your facility:

• Belt tracking and tensioning components are critical to ensure proper alignment.
• Supports and rollers need adjustment capabilities to keep belt centered.
• Require greater precision in belt fabrication and welding for optimal performance.
• May need guards or protective equipment depending on operational safety risks.
• Workstations should be ergonomically designed for easy access from multiple points.

Leading Manufacturers of Bottomless Conveyor Systems

Several specialty industrial equipment companies design and build bottomless conveyors. Some of the top manufacturers known for engineering high-performing, durable systems include:

• FlexLink - Global conveyor system designer with patented dynamic belt tensioning.
• Allied Conveyor Systems, Inc. - Custom bottomless conveyors for 50+ years.
• bands conveyors
• Dorner - Precision fabrication with integrated automation capabilities.
• Triple/S Dynamics - Robust modular plastic conveyor belt systems.

The Future of Bottomless Conveyor Technology

As manufacturing processes grow more advanced and customized, bottomless conveyors are likely to expand in usage and versatility. Some possible innovations in development include:

• Wearable technology integration - Sensors for real-time belt monitoring and predictive analytics.
• Improved belting materials - Smart fabrics or ultra high molecular weight plastics for extended wear life.
• Vision systems - AI-enabled camera systems to control product flows dynamically.
• Human-machine collaboration - Robotics programmed to safely interact with human workers.
• Modular reconfiguration - Interchangeable sections for quickly altering layouts.

These and other innovations will drive the implementation of more intelligent and flexible bottomless conveyor solutions across far-reaching industries in upcoming years.

FAQs

What is a bottomless conveyor?

A bottomless conveyor is a specialized conveyor system that lacks side walls along the belt. This allows products to be accessed from any point, rather than just the end, for improved flexibility and integration with other equipment.

What industries use bottomless conveyors?

Bottomless conveyors are used across many industries including food production, packaging, manufacturing, order fulfillment, and warehousing. Their modular design works well for custom production lines.

What types of items can be transported on bottomless conveyors?

These conveyors work well for small to medium sized products up to about 50 pounds. Special heavy-duty designs can handle heavier loads. Irregular shaped items or bulk materials may not be suitable.

What safety precautions should be taken with bottomless conveyors?

As with any conveyor system, bottomless types may require guarding, emergency stops, employee training, and safe work procedures. Any identified hazards should be addressed by a qualified safety professional.