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Market Overview: The global conveyor systems market, which includes hanging conveyor systems, reached an estimated value of $58.8 billion in 2023 and is projected to grow to $82.9 billion by 2030, with a compound annual growth rate (CAGR) of 5.0% during this period, according to Global Industry Analysts. Notably, the Belt Conveyor Systems segment is expected to drive growth, reaching $21.2 billion by 2030, while Roller Conveyor Systems are set to grow at a higher CAGR of 6.2%. This growth trajectory indicates a rising demand for efficient material handling solutions across various industries, reflecting a shift towards automation and enhanced production capabilities.
Regional Insights: The U.S. market for conveyor systems was valued at $14.5 billion in 2023, with China also showing robust potential, forecasted to grow at an impressive CAGR of 6.9% to reach $14.5 billion by 2030. This regional growth is driven by increasing investments in manufacturing and logistics sectors, where hanging conveyor systems offer significant advantages in space-saving and efficiency. Additionally, consumer behavior is shifting towards automated solutions that reduce labor costs and streamline operations. As businesses adapt to these trends, the demand for hanging conveyor systems is likely to increase, positioning them as a crucial component in modern manufacturing and distribution processes.
The hanging conveyor system refers to a type of product transportation equipment that hangs products from the top of a rail. Various types of hanging conveyor systems are available that work well in specific environments.
Hanging roller conveyors
A roller conveyor system uses gravity to help move products along its surface. Products will rest on top of small cylindrical rollers that spin freely. This system requires a slight downward slope to push products along. For flat surfaces, manual push or lateral forces will be needed to move objects. The roller's ability to turn makes it a great candidate for moving products of all shapes and sizes. One of the major benefits of this conveyor style is that it can accommodate large and heavy objects compared to other conveyor types.
Hanging chain conveyors
Hanging chain conveyors often feature magnetic forces to help move products along its chain. The chain is made out of metal and is bent into a circular shape while hanging from a rail. Products will be attached to the chain through a magnet that holds it in place. Once the magnet releases power, it will then release the item. An upside-down power source is needed to move items on a chain conveyor. These conveyers can support assemblies in a wide range of industry segments such as foundries, component assembly, and many other applications.
Hanging belt conveyors
A belt conveyor system is often very easy to identify and is the most popular type of conveyor. The belt can hang off an upper rail or support itself with multiple the use of multiple rollers along the bottom. Products will rest on a top soft fabric belt that moves products from the bottom to the top. Belts can be made out of different types of material but are usually made out of cloth or leather.
Flexibility:
The design of a hanging conveyor allows the system to bend and twist around obstacles and adjust the spacing between different suspension points. This enables the conveyor system to traverse around various facilities, setups, and structures smoothly.
Load capacity:
Hanging conveyors can carry heavy loads because of the sturdy materials typically used to fabricate them. They can be made to support substantial weight, like bulky containers or enormous, heavy products requiring two or more individuals to bear them. Moreover, the number of items transported, the speed at which they are moved, and the frequency with which they are used may all be factors in determining how much weight these systems can handle.
Speed:
Speed refers to how quickly the conveyor can move items from one location to another, typically measured in meters per minute. Products are moved through the manufacturing process by hanging conveyors at a specific pace, reducing the need for human labor under circumstances that may otherwise require two or more individuals to bear an item.
Material:
The materials utilized to construct a hanging conveyor, such as aluminum, steel, or plastic, which may have distinct characteristics and use scenarios. For instance, plastic has superior abrasion resistance, chemical resistance, and durability compared to metal. In addition, a greater quality polypropylene can provide food-grade conservation more than rust-proof steel can.
Hanging conveyor systems need regular maintenance to ensure they perform optimally. Some of the maintenance tips include
The materials and application of the hanging conveyor system vary in different industries. Here are some hanging conveyor system usage scenarios.
Automotive assembly lines
Manufacturers use the heavy-duty hanging conveyor system to transport various automotive parts, such as car frames, panels, dashboards, etc., in the assembly process. The conveyor can be adjusted to different assembly line heights. Plus, it allows workers to access the parts from multiple angles. This improves efficiency and productivity during the assembly process.
Manufacturing process of electronics
Electronics manufacturers often use a compatible speed hanging conveyor system to transport items like circuit boards, switches, and screens. This ensures that the electronics are produced quickly and accurately. The conveyor system can be paused so that assembly workers can focus on a specific part. This helps improve the production efficiency and accuracy of the electronics.
Food processing and packaging
Food and beverage manufacturers use the hanging conveyor system to move bottles, cans, and other containers through the production and packaging processes. This helps optimize floor space. The items can be easily routed to different processing stations or packaging lines. Workers can quickly access them from different angles.
Clothes production and assembly
In the garment factory, a hanging conveyor carries clothing items like shirts, pants, and jackets. These clothing items go through different processes, such as sewing, ironing, and final inspection, efficiently. The adjustable height feature of this conveyor system allows workers to ergonomically handle the clothing items, which improves their productivity.
Heavy-duty construction projects
In the mining, oil and gas, or material handling industries, workers use a heavy-duty hanging conveyor to move heavy items, tools, or equipment between different work areas or levels. This helps optimize space and meet the demanding requirements of these industries.
When choosing the right hanging conveyor system for a specific application, it is important to consider several factors.
Payload requirements
The payload requirements of an item are typically the weight of an item plus any additional handling requirements. It is important to determine if the weight can be safely handled by a specific conveyor system. A frame system with different hooks that can be adjusted to carry different items, such as clothes, is usually used for light and bulky items. For heavier and bulkier weights, roller conveyors or power and free systems are more applicable.
Speed and throughput
It is important to consider the system speed and throughput. For instance, power conveyors are ideal for lower-speed and high-load applications, while roller conveyors and monorails are suitable for high-speed applications.
How an item moves through a process should also be determined. The number of items that need to be handled per hour affects system selection, along with other factors such as method of power and braking requirements.
Floor space and layout
Floor space and layout are very important when determining how to position the system and ensure it fits within a space. Space-saving vertical lifts are useful for reducing floor space, while a monorail is ideal for long, horizontal spaces. Roller conveyors are ideal for open spaces on the ground.
Integration and flexibility
Conveyor systems are linked to other flows or processes, such as receiving goods or shipping or even other processing equipment. Therefore, a system that is flexible will be suited for other processing and programs.
Energy efficiency and sustainability
Energy-efficient and sustainable systems are ideal for reducing carbon footprints and energy use. Gravity roller systems make use of natural forces, and efficient drive motors in power systems reduce energy use.
Q1: How to install a hanging conveyor system?
A1: The installation of a hanging conveyor system requires some preparations, such as reading the installation manual and preparing the installation tools. Then, unpack the components one by one, and check them against the invoice and packing list to see if there are any missing parts. After that, install the main frame of the conveyor system, and hang or support it on the building or floor. Finally, install the different components onto the main frame.
Q2: What are some uses of a hanging conveyor system?
A2: An overhead conveyor system has a wide range of applications in various industries, such as product assembly, automated storage, and retrieval, manufacturing and production lines, material handling, packaging, automotive industry, and garment industry.
Q3: How does a hanging conveyor system work?
A3: A hanging conveyor system moves products or materials from one point to another along an overhead track. It usually employs a power unit that drives the conveyor system, pushing or pulling forces acting on the load, and auxiliary components like sensors and controllers for the smooth operation.
