Inline Box Conveyor System
High-throughput carton and case handling for modern warehouses and production lines.
The Inline Box Conveyor System from GlobalRoll is engineered for high-volume movement of cartons, cases, and totes through picking, packing, and shipping operations. Built on standardized, template-driven modules, this system delivers reliable flow, consistent performance, and easy configurability for a wide range of facility layouts and product mixes.
Applications & Use Cases
The Inline Box Conveyor System is ideal anywhere cartons and cases need to move quickly, safely, and predictably.
- Case and carton handling in distribution and fulfillment centers
- Infeed and outfeed between production and packaging lines
- Conveyor runs feeding sortation, print-and-apply, or scanning systems
- Order picking, consolidation, and staging zones
- Buffering and accumulation between workstations or processes
- Shipping lanes connecting packing stations to dock doors
System Overview
The Inline Box Conveyor System is built around precision rollers, modular frames, and configurable drive packages designed specifically for carton and case handling. Straight sections, curves, merges, and transfers can be combined to create clean, efficient product flow from one end of your facility to the other.
Instead of re-inventing the design for every project, GlobalRoll uses engineered templates for the Inline Box family. Each module—whether it’s a straight run, curve, or merge—has defined dimensions, component options, routings, and QA steps. This template-driven approach gives you a proven, reliable system while still letting you configure the width, length, roller specs, speeds, and accessories to match your exact requirements.
Key Features & Benefits
Features
- Template-driven design built specifically for carton and case handling
- Standardized straight sections, curves, merges, and transfers
- Configurable roller options (diameter, material, coatings, bearings)
- Robust structural frames with multiple support and guard options
- Flexible drive configurations, including fixed-speed and variable-speed drives
- Integration-ready for scanners, print-and-apply, labeling, and sensors
- Optional accumulation zones for controlled product spacing and buffering
Benefits
- High throughput: Keeps cartons and cases moving smoothly through packing, sortation, and shipping.
- Reliable operation: Standardized modules and proven components reduce downtime and troubleshooting.
- Flexible layouts: Modules can be combined and reconfigured to match changing processes or building constraints.
- Easy expansion: Template-driven design makes it straightforward to add new sections or extend the line later.
- Predictable costing: Standardized modules and BOMs support accurate budgeting and quoting.
- Better visibility: Consistent component selection and documentation simplify maintenance and planning.
Configuration Options
Every Inline Box Conveyor System is built from standardized modules, then configured to fit your building, product range, and throughput goals.
Mechanical & Dimensional Options
- Length Range: Short sections for workstation-to-workstation moves up to extended runs spanning entire facility zones
- Width Range: Effective conveyor widths sized to typical carton and tote dimensions (custom widths available)
- Elevation: Fixed-height or adjustable-height supports; options for gentle inclines/declines as needed
- Robust structural frames with multiple support and guard options
- Roller Specifications: Multiple diameters and wall thickness options; steel or coated rollers; appropriate bearings for load and duty cycle
- Frame Materials: Heavy-duty steel construction with durable finishes; stainless options available for select environments
- Support Options: Floor-mounted stands, ceiling-hung supports, and hybrid support designs to work around existing equipment
Drive, Control & Zone Options
- Drive Types: Traditional drive packages, motorized roller sections, or a combination depending on layout
- Speed Range: Configurable line speeds to match upstream and downstream processes
- Zone Control: Optional zero-pressure or minimum-pressure accumulation zones for product spacing and buffering
- Sensors: Photo-eyes for jam detection, presence sensing, and accumulation control
- Control Interface: Designed to integrate with your PLCs, networks, and existing automation infrastructure
Available Accessories
- Side guides for carton alignment
- End stops, gates, and diverters
- Transfers and merges to connect multiple lines
- Guardrails and safety guarding options
- Mounting provisions for scanners, labelers, and print-and-apply systems
- In-feed and discharge accessories to connect with other equipment
Technical Highlights
Specific values will depend on your configuration, but Inline Box Conveyor Systems typically fall within these ranges:
- Typical Load Capacity: Designed for common carton and tote weights per zone or per linear foot (exact values sized for your application)
- Maximum Line Speed: Configurable to match required throughput and upstream/downstream equipment
- Environment: Ideal for dry, ambient warehouse and production environments; special configurations available for other conditions
- Power: Standard industrial power options based on region and drive selection
- Materials: Heavy-duty steel frames with durable finishes; roller and component materials selected to match product and duty cycle
Typical Layouts & Use Cases
A typical Inline Box Conveyor System starts near case erecting, picking, or production areas and moves cartons through packing, scanning, and labeling before routing them to shipping lanes or palletizing stations. Straight runs link work cells, curves navigate around building columns and equipment, and accumulation zones create buffers so downstream processes are never starved or flooded.
Example Use Case
A distribution center needed to move cartons from multiple picking zones into a consolidated packing and shipping area. GlobalRoll configured an Inline Box Conveyor System with multiple infeed lines feeding a main trunk conveyor, integrated accumulation zones before packing stations, and a final branch to multiple shipping lanes. The standardized modules allowed the facility to adjust the layout as volume grew, while maintaining reliable flow and predictable maintenance.
Quality, Traceability & Maintenance
Inline Box Conveyor Systems are built under GlobalRoll’s engineering-controlled standards. Each module is defined in our templates with specific BOMs, routings, and QA checkpoints. This structure ensures that what’s installed at your site matches what was engineered and documented.
Key components—such as drive units, critical rollers, and control modules—can be tracked through manufacturing and QA. That traceability helps you manage spares, plan maintenance, and quickly identify the right parts when changes or expansions are needed.
Modules are designed with maintenance in mind. Standardized components make it easy for your team or service partners to inspect, replace, and expand the system without guessing which parts were used. Access to rollers, drives, and sensors is considered in the layout so maintenance tasks can be completed efficiently and safely.
Ready to Configure Your Inline Box Conveyor System?
If you’re planning a new line or upgrading an existing carton or case handling system, we can help configure an Inline Box Conveyor layout around your building, product mix, and throughput targets. We’ll start by understanding your current flow, constraints, and goals—and then configure a solution using proven, template-driven modules.
Downloads & Resources
Use these documents to support design reviews, budgeting, and internal planning.
- Inline Box Conveyor System Overview (PDF)
- Inline Box Conveyor Technical Datasheet (PDF)
- Conveyor Layout Planning Checklist (PDF)
- Maintenance & Inspection Quick Guide (PDF)