Gravity Conveyors

Gravity conveyors are a cost-effective and versatile transportation solution on warehouse floors throughout the world. They harness the natural force of gravity to move items. They optimize for efficiency and minimize labor — all without wires or electricity.

These non-powered material handling solutions are highly customizable. They often integrate with other warehouse systems like carts and scales for streamlined picking, packing, and other transport-related applications.

The Basics of Power Conveyors 01

Core Considerations for Gravity Conveyors 02

Know Your Load 03

Gravity Conveyor Lifecycle 04

The Basics of Gravity Conveyors

Gravity conveyors are set on a slope and use momentum to push loads down the line. Unlike a powered conveyor, which requires a power source to generate movement, gravity conveyors allow items to flow freely.

Gravity conveyors have a simple design with two primary components:
The frame (often made from aluminum or steel)

The roller device

There are two main types of roller devices for gravity conveyors:

Rollers

Roller conveyors use tube-shaped rollers connected to the frame. The rollers rotate to enable forward movement. They are typically most useful for heavier loads.

Skatewheels

Skatewheel conveyors use a system of small, round wheels that rotate as the load moves across. These are often best for high-volume, low-weight items. That makes them particularly useful in the food and beverage industries.

Keep in mind that many bend, curve, and merge conveyors can also use the gravity method.

Thanks to their streamlined setup, gravity conveyor systems are cost-effective compared to powered conveyor solutions. And they’re highly versatile.

You can also configure these non-powered conveyors to your precise specifications. That makes them helpful for both light-duty and heavy-duty operations across various industries, including warehouses, distribution centers, and manufacturing facilities.

Core Considerations for Gravity Conveyors

When it comes to purchasing the right conveyor system for your facility, you’ll need to keep several key factors in mind. Don’t mistake the simple construction of a gravity conveyor system for an excuse to not pay close attention to these considerations:

Roller Type

Rollers are critically important because they are in direct contact with the load.

The type of roller you choose will depend on the product you’re moving (weight, size, and material), as well as facility conditions.

For heavier products, steel tube rollers are often the best choice thanks to their durability and load-bearing capacity. Lighter items, on the other hand, may work well with smaller-diameter or plastic rollers, which help reduce noise and cost.

You’ll also want to consider factors like moisture, temperature, and potential debris — for example, sealed bearings are ideal in dusty or damp environments.

Roller Centers

To keep your product safe, at least three rollers must always be in contact with the load.

That means the spacing between rollers — known as the roller centers — has to match the length and bottom surface of your product. If the rollers are spaced too far apart, smaller items can tip, get stuck, or fall through.

Frame Capacity

The frame is the backbone of the conveyor. It has to support the weight of the mechanism and the product being moved.

Factor product and location specifications into your overall capacity calculations.

Roller Order Settings

Roller order settings refer to the position of the rollers relative to the frame.

There are two core options:

High roller setting, where the rollers sit on top of the frame.
Low roller setting, where the rollers sit below the top of the frame.

The right choice depends on the size, shape, and stability of your product. High roller settings are best for larger, more stable items because they make loading and unloading easier. Low roller settings are good for smaller or unstable items that might shift or fall off during movement.

Conveyor Slope

Conveyor slope is the pitch or incline of the gravity conveyor. It determines the flow rate and speed of the products down the line.

The proper slope depends on numerous factors, such as the product (size, weight, surface area) and the roller type (size, configuration, spacing).

Heavier items, for example, often need a gentler slope to avoid going too fast. Meanwhile, lighter products or those with more surface friction may need a steeper incline to keep them moving. Testing is often the best way to fine-tune the slope on your gravity conveyor.

Know Your Load

Still wondering what type of gravity conveyor will suit your facility best? The perfect place to start is understanding the load you need to transport. Your product plays a key role in shaping the type, size, configuration, and operation of the conveyor you purchase.

Take note of your product’s size, weight, and surface area. For optimal conveying, unit loads should have a flat, stable surface. Avoid irregular or broken boards, protruding nails, and loose items. Use tote boxes, carrier boards, or pallets for smaller or oddly shaped items.

Load Type

There are several different load types. Each will demand different slope, capacity, and conveyor configuration. A few common load types include:

Cartons. Typically work well with a moderate slope and standard roller spacing, as long as the bottoms are flat and rigid. Lightweight cartons may need a steeper slope to maintain flow.
Cases. Because they’re heavier than cartons and usually more stable, cases often need sturdier rollers and a gentler slope to prevent excessive speed.
Totes. Totes with solid, flat bottoms are great for gravity conveyors, but open-bottom or soft-sided totes may need to ride on a carrier board.
Drums. Thanks to their weight and curved surfaces, drums need wide, heavy-duty rollers and a very gentle slope. Some facilities use containment rails to keep them in line.
Bags. Flexible or soft bags need a carrier board or tray because their shape won’t reliably span multiple rollers.

Operating Conditions

Operating conditions also play a role in your understanding of your gravity conveyor needs, especially as it relates to bearings:

A plain bearing is sufficient for clean environments.
Consider a greasable bearing for hot environments.
A dust-tight bearing is usually best for dusty environments.

Get in touch with the East Coast Storage Equipment team if you have any questions.

Choose the Right Gravity Conveyor for Your Facility

If you want to know which kind of gravity conveyor is right for your business, call our team at 888.294.5022. Our material handling equipment experts are ready to help you find the perfect gravity conveyor for your business.

Gravity Conveyor Lifecycle

Installation

While most conveyor sections come preassembled, you still need to follow certain standards as you install them.

First, always install equipment according to the elevations shown in the layout drawings. Setting the initial first elevation is critical to setting the rest of the points. A mistake here will lead to more trouble down the line.

Consider adjustments for floor level changes, like moving to an upper or lower floor. Always install anchoring according to the manufacturer’s instructions.

Inspection

Run the conveyor with a moderate load and observe the products as they travel along the entire length of the system. Listen for abnormal noises or vibration from the conveyor’s bearings and rollers.

Address any issues right away. And make sure the supports are properly aligned to achieve the product flow and orientation you want. Remove any dirt buildup on the skatewheels or rollers that could hinder smooth operation.

Finally, inspect the wheels or rollers for signs of damage. Replace any faulty components immediately.

Maintenance

With fewer parts comes less maintenance — that’s the good news. However, gravity conveyors still need a regular maintenance cycle to extend their shelf life, comply with regulations, and keep your products and people safe.

A good rule of thumb is to inspect rollers, frames, and fasteners monthly. And do a more thorough check — including cleaning and lubrication where applicable — every three to six months, depending on how much you use the system.

Replacement

Even with a strict maintenance and inspection schedule, you will eventually need to replace or repair your gravity conveyor system.

If your system needs a refresh, contact our experienced team at East Coast Storage Equipment. We’re always happy to help.

What to Know About Gravity Conveyor Maintenance

Gravity conveyors’ simple design and operation offer a key benefit: limited maintenance needs.

While regular inspections are still critical, the self-contained nature of a gravity conveyor system — whether that’s a skatewheel or roller unit — means most maintenance revolves around periodic part replacements and regular lubrication. This includes a general inspection of the equipment and checking all nuts and bolts for proper tightness.

While you should always consider local and Occupational Safety and Health Administration (OSHA) standards, here are some general guidelines for ongoing mechanical maintenance for gravity conveyors:

Skatewheels

Periodic lubrication. Monthly