Overhead conveyors for lightweight parts are often overlooked when discussing conveyor systems, as the common image tends to focus on those designed to move large and heavy components. However, the efficient transportation of lightweight parts, such as metal components, housings, boxes, or injected parts, is just as crucial in many industries. Just because these parts are lighter doesn’t mean they require less planning.
If your plant still relies on forklifts or operators moving boxes manually, you’re losing both efficiency and money. Overhead conveyors for lightweight parts can optimize these processes and transform your internal logistics.
What are lightweight parts in the industry?
We call lightweight parts those components whose weight does not present a significant logistical challenge, but whose handling must be precisely planned. In sectors such as automotive, home appliance manufacturing, and logistics, some examples include:
- Bumpers and plastic panels in the automotive industry.
- Housings and structures of home appliances.
- Empty boxes used in logistics and distribution systems.
- Plastic and metal components at assembly stations.
- Reusable containers in picking and sequencing processes.
In many cases, these parts are not heavy, but their volume or fragility requires an efficient transportation system. Additionally, when they need to be moved in sequence, automation helps avoid congestion and unnecessary manual handling.
Why use an overhead conveyor?
Overhead conveyors have proven to be one of the most efficient solutions for moving materials without interfering with floor space. While they are often associated with heavy loads, their implementation in the transportation of lightweight parts offers key advantages.
1. Not everything has to be moved on the floor
The space in a plant is limited, and production areas cannot afford interruptions caused by forklift traffic or overcrowded accumulation zones. An overhead conveyor on a second level frees up floor space and optimizes the layout.
2. No interruptions in production flow
Traditional manual transport methods create downtime. An overhead conveyor allows parts to be moved without operators transporting them from one place to another, ensuring continuous, uninterrupted production.
3. Protection for fragile or finished parts
The risk of bumps, scratches, or deformations in fragile or painted parts is high when transported manually or accumulated in storage areas. A conveyor where the part is hung minimizes handling and reduces the risk of damage.
4. Flexibility and adaptability
An overhead conveyor not only transports parts from one point to another. It can incorporate intermediate buffers, sequencing systems, and inspection stations, allowing full integration with the rest of the internal logistics.
5. Reduction of operating costs
Reducing manual handling of parts and the use of forklifts helps optimize plant processes. Additionally, minimizing production downtime translates into cost reduction and greater operational efficiency.
Overhead conveyors specifically designed for lightweight parts
Not all overhead conveyors are designed for heavy loads. For the movement of lightweight parts, chain and skid conveyors are often oversized solutions. These systems require more energy, more complex maintenance, and take up unnecessary space in the plant.
Chain conveyors require constant lubrication and frequent inspections, while skids need more robust and expensive structures. Both systems work well for heavy loads, but when it comes to lightweight parts, there are more efficient and economical alternatives.
Esyconveyor is an overhead conveyor specifically designed for lightweight parts. Instead of relying on complex systems, it moves thanks to a Kevlar rope, a durable, lightweight, and maintenance-free material.
Advantages over traditional systems:
- Cleaner transport, without dirt buildup or lubrication residue.
- Less maintenance, eliminating constant adjustments and frequent inspections.
- Greater efficiency and lower investment, with reduced energy consumption and a lighter structure.
This type of system allows production flow efficiency to be maintained without oversizing the investment. It is an ideal solution for plants handling large volumes of lightweight parts.
Use cases: Where are overhead conveyors for lightweight parts being implemented?
Here are some sectors and applications where conveyors for lightweight parts are being successfully used.
Automotive industry
- Transporting exterior car parts before and after the painting process.
- Moving parts in sequence for assembly lines.
Home appliance manufacturing
- Plastic housings and lightweight components moving between assembly stations.
- Optimizing production flow by reducing manual handling.
Logistics and distribution centers
- Transporting empty boxes in pharmaceutical and consumer goods warehouses.
- Sequencing buffers to optimize picking and dispatch times.
Food industry
- Transporting products in process, reducing manual handling, and ensuring optimal hygiene conditions.
- Origin in the meat industry: The first overhead conveyors were used to move large pieces of meat, improving ergonomics and reducing handling times. Additionally, they avoided contact with surfaces, ensuring greater food safety.
Key factors for implementing overhead conveyors for lightweight parts
Each plant has different needs, so it is important to define some key aspects before implementing an overhead conveyor:
- Layout design and optimization of the conveyor route.
- Load capacity and compatibility with the parts to be transported.
- Possibility of integrating accumulation systems and intermediate buffers.
- Automation of part tracking with RFID or barcodes.
Manual or automatic?
Not all overhead conveyors need to be automatic. There are manual systems that are an excellent alternative for certain applications.
A manual overhead conveyor is an efficient option for continuously moving parts over short distances. It also allows temporary storage or the creation of intermediate buffers without the need for complex automation.
Advantages of manual systems include:
- Greater control by the operator, ideal at stations where pieces need to be inspected or verified before continuing the process.
- Lower costs, as they do not require motors or advanced automation.
- Easy installation and flexibility, as they are simple to install and can be easily expanded.
- Ergonomics and safety, allowing the operator to handle pieces with less effort and reducing the risk of damage to the product or personal injury.
This solution is ideal for accumulation warehouses and picking areas. It is also useful in processes where occasional handling of pieces is needed before continuing the workflow.
An automatic overhead conveyor is ideal for optimizing time and reducing human intervention. It also ensures a constant flow of materials without production interruptions.
The choice between manual and automatic depends on the type of operation, the volume of parts to be moved, and the need for synchronization with other processes.
Esypro: Experts in overhead conveyors for lightweight parts
At Esypro, we are experts in the transportation and storage of lightweight parts. We design solutions that optimize material flow without oversizing the investment, ensuring efficiency, flexibility, and smart use of space in every industry.
If your plant still handles lightweight parts with traditional systems, it’s time to take the next step. Contact us and discover how to improve your internal logistics with an overhead conveyor designed for your operation.