Pallet handling is one of the most demanding applications in material flow — and selecting the wrong conveyor type can mean costly downtime, maintenance headaches, or a system that simply can’t keep pace with production. The right choice starts with understanding your pallet and your process.
Chain conveyors are the workhorses of pallet transport. Robust and reliable, they handle heavy unit loads with ease and are well-suited to accumulating pallet loads, transferring between lines, or staging product in a warehouse environment. For heavier pallets — think 1,000 kg or more — chain-driven live roller (CDLR) or strand chain conveyors are typically the preferred solution, offering positive drive with minimal maintenance exposure.
Roller conveyors, either gravity or powered, are popular where cost and flexibility are priorities. Powered roller conveyors allow controlled accumulation and zone-by-zone operation, making them ideal for pick stations or buffer lanes. Gravity roller lines work well on inclines or in manual handling zones where operators sort or stage loads by hand.
Skate wheel conveyors and turntables round out common pallet-handling systems, providing smooth directional changes and 90° transfers without the need for complex mechanical drives.
Key factors to nail down before specifying any system: pallet dimensions and weight, floor space constraints, throughput rate, accumulation requirements, and whether loads will be handled in a controlled environment (cold storage, clean room, or hazardous area). Getting these parameters right upfront is the difference between a system that runs for decades and one that’s retrofitted within the first year.
At GCI, we’ve engineered pallet handling solutions across food processing, pharmaceutical, and heavy manufacturing — and we’re happy to help scope the right system for your application.
