If you’re running a business that involves moving products — whether it’s a manufacturing line, a warehouse, or a packaging facility — chances are you’ve looked at installing conveyors.

And you’re in good company. Conveyors have been transforming how businesses handle materials for decades. But with so many types available, figuring out which one is best for your business can feel overwhelming.

When people ask me where to start, I always tell them this: Don’t pick a conveyor because it’s trendy. Pick one that fits your space, your materials, and your process. That’s the real secret to getting value from your investment.

In this guide, I’ll walk you through the key considerations and how to match a conveyor belt system to your actual business needs.

Know what you’re moving

It sounds obvious, but it’s often overlooked — what are you moving on the conveyor?

This drives everything else. Different materials behave very differently:

✅ Rigid items like boxes, cartons, and pallets
✅ Fragile goods like glassware
✅ Loose bulk materials (grains, powders, etc.)
✅ Temperature-sensitive items
✅ Food-grade products requiring hygienic surfaces

One client of mine — a craft brewery — initially thought they’d need a powered belt conveyor for moving kegs. But after reviewing their space and workflow, we found that a roller conveyor system was far more cost-effective and flexible.

Map out your space

Next: space planning.

Before you even look at conveyor types, take a good, hard look at your facility:

✅ Floor space available
✅ Ceiling heights and clearances
✅ Obstacles (pillars, doors, existing equipment)
✅ Entry and exit points for materials

I’ve seen businesses install beautiful conveyor systems — only to discover they block access to key equipment or violate safety clearances. It pays to plan this up front.

Speed and flow matter

Another big factor: how quickly does your product need to move?

  • High-speed production line? You’ll want motorised conveyors with good speed control.
  • Manual packing area? A simple gravity conveyor might do the job.
  • Mixed flow (some fast, some slow)? Modular systems that can be adjusted are ideal.

It’s amazing how many bottlenecks I’ve seen caused by mismatched conveyor speeds. Always align conveyor flow with your process.

Prioritise safety and compliance

Whatever conveyor system you choose, safety should be baked in.

Australian standards around conveyors are clear, and for good reason. Poorly designed systems can cause serious injuries.

A great resource is the conveyor products and solutions safety guidelines.

You’ll want to ensure:
✅ Guards on all pinch points and moving parts
✅ Emergency stop cords and switches
✅ Safe load ratings posted
✅ Maintenance access without risk

And here’s a pro tip: the best conveyor suppliers will help you navigate this during design — make sure you ask.

Match conveyor type to your needs

Let’s quickly run through some common types:

Belt conveyors

✅ Great all-rounders
✅ Handle a wide range of items
✅ Good for steady movement and inclines/declines

Roller conveyors

✅ Fantastic for cartons, crates, and boxes
✅ Modular and flexible
✅ Can be powered or gravity-driven

Chain conveyors

✅ Tough and reliable
✅ Handle heavy loads like pallets or steel products

Overhead conveyors

✅ Free up valuable floor space
✅ Great for paint shops, assembly lines, or garment handling

The trick is not to fall in love with one type — often, a combination of conveyors works best.

Think about growth

I can’t stress this enough — plan for the future, not just today.

Will your product range change? Will volumes increase? Could your facility layout evolve?

That’s why I love roller conveyor systems — they’re modular, scalable, and can be reconfigured easily as your business grows.

Maintenance and reliability

Downtime kills efficiency, so reliability and serviceability are key.

When evaluating systems, ask about:
✅ Expected service intervals
✅ Local support and spare parts
✅ Manufacturer warranty terms
✅ Ease of cleaning (critical for food and pharma environments)

I’ve seen businesses choose cheap conveyors — only to regret it after constant breakdowns. Sometimes spending a little more upfront saves a fortune in the long run.

Understand the total cost of ownership

It’s easy to focus on the sticker price, but savvy buyers look at the total cost of ownership:

✅ Energy efficiency (especially for powered conveyors)
✅ Long-term maintenance costs
✅ System lifespan
✅ Flexibility to adapt over time

For example, one client switched from an old chain conveyor to a modern belt system — slightly more expensive upfront, but saved them thousands per year in energy costs.

Stay informed on belt conveyor trends

I always encourage clients to keep an eye on where the industry is going — even if they’re not ready for cutting-edge tech today.

Latest trends in belt conveyor design include:
✅ Smarter sensors for predictive maintenance
✅ Advanced belt materials for longer life
✅ Modular components for faster repairs
✅ Integration with warehouse management systems (WMS)

Even small upgrades here can deliver major ROI.

Final thoughts

Choosing the right conveyor system is about more than moving things from A to B — it’s about supporting your people, your process, and your future growth.

My parting tips:
✅ Understand your materials first
✅ Plan your space carefully
✅ Match conveyor type to your actual workflow
✅ Prioritise safety and flexibility
✅ Think about long-term ROI, not just upfront cost

And remember — you don’t have to do this alone. Good conveyor suppliers are consultants as much as they are equipment sellers. Lean on their expertise — it’ll help you build a smarter, more efficient system.

The right conveyor system can transform your business. Take the time to choose well — you’ll thank yourself later.