Multi-Lane Merge Conveyor System
Coordinated product flow from multiple lanes into a single, controlled conveyor stream.
The Multi-Lane Merge Conveyor System from GlobalRoll is designed to combine product from two or more infeed lanes into a single outbound conveyor at controlled speeds and spacing. Using synchronized drives, precise controls, and configurable merge logic, this system helps balance upstream workflows, feed sorters and pack stations efficiently, and keep your outbound flow smooth—even when multiple lines are running at once.
Applications & Use Cases
Multi-lane merge conveyors are ideal wherever multiple product streams must be combined into one controlled flow.
- Merging multiple picking or packing lines into a single sortation conveyor
- Combining several order-processing lanes into one shipping feed line
- Feeding cartons or totes from multiple mezzanine modules into a trunk conveyor
- Balancing product from parallel production or packaging machines
- Managing flows from manual and automated areas into shared downstream equipment
- Creating priority or sequenced merges for different order types or destinations
System Overview
GlobalRoll’s Multi-Lane Merge Conveyor System uses a combination of infeed conveyors, merge sections, and control logic to coordinate product flow from multiple lanes into one. Lane speeds, product spacing, and release timing are managed so that cartons or totes enter the merge point in a smooth, predictable pattern—without collisions or uncontrolled bunching.
The multi-lane merge family is defined in our product templates with standardized merge modules, roller or belt sections, controllers, and sensor configurations. We configure these templates based on the number of infeed lanes, required throughput, product dimensions, and downstream equipment needs. This template-driven approach ensures consistent performance, clear documentation, and an easier path to future expansion or reconfiguration.
Key Features & Benefits
Features
- Configurable multi-lane merge modules (2-lane, 3-lane, and higher)
- Controlled product spacing and release logic at the merge poin
- Synchronization of lane speeds and merge conveyor speeds
- Sensor-based detection of product presence and gaps for optimized merging
- Compatible with roller, belt, or accumulation infeed conveyors
- Integration-ready with print-and-apply, scanners, sorters, and downstream systems
- Standardized control strategies for high-throughput merge operations
Benefits
- Higher throughput: Efficiently uses downstream capacity by feeding product in a controlled, optimized stream.
- Smoother flow: Reduces jams, pileups, and rushes caused by unmanaged lane convergence.
- Better utilization: Allows multiple upstream lines to share the same sorter, pack area, or shipping conveyor.
- Flexibility: Merge logic can support priority rules, order types, or lane-based sequencing.
- Scalability: Template-based modules allow additional lanes or expanded capacity in the future.
- Maintainability: Standardized components and controls simplify troubleshooting and maintenance.
Configuration Options
Each Multi-Lane Merge Conveyor System is configured from standardized GlobalRoll modules to match your lane count, product mix, and throughput goals.
Mechanical & Dimensional Options
- Number of Infeed Lanes: Common configurations include 2-lane and 3-lane merges; higher counts available as required
- Conveyor Width: Infeed and merge widths sized to your cartons or totes, with proper side clearance
- Section Lengths: Infeed, acceleration, and merge sections configured to provide needed spacing and stabilization
- Conveyor Types: Roller, belt, or mixed conveyor types depending on product and line design
- Layout Geometry: Straight merges, angled merges, or side-by-side convergence depending on facility constraints
Drive, Control & Merge Logic Options
- Drive Packages: Motors and drives sized to maintain target speeds and accommodate varied loads
- Speed Control: Fixed or variable-speed control for infeed and merge sections to manage spacing and throughput
- Merge Logic: First-in-first-out, alternating-lane, weighted priority, or custom sequence rules
- Sensors: Product detection sensors, gap sensors, and jam detection at key control points
- Control Integration: Designed to tie into your PLCs, sorters, scanners, and line control systems
Available Accessories
- Side guides and guardrails to maintain product alignment
- Lane dividers and funnels for clean product presentation at the merge
- Status indicators and stack lights for lane/merge status visibility
- Bypass paths or manual divert options where needed
- Interfaces for upstream scales, scanners, or dimensioning systems
Technical Highlights
Exact specifications are customized per application, but Multi-Lane Merge Conveyor Systems typically include:
- Lane Count: Configured for required number of infeed streams (2, 3, or more)
- Design Throughput: Sized for target cartons/totes per hour through the merge
- Line Speeds: Infeed and merge speeds tuned to support desired throughput and spacing
- Product Size Range: Engineered to handle minimum and maximum product dimensions reliably
- Environment: Suitable for typical indoor warehouse, distribution, and production environments
- Power & Controls: Industrial power configured to facility standards, with PLC integration for logic and monitoring
Typical Layouts & Use Cases
A common Multi-Lane Merge layout uses two or three infeed lines—each coming from a separate pick zone, pack area, or mezzanine module—joining into a single trunk conveyor that feeds a sorter or shipping lane. Infeed lines are equipped with accumulation or zone control to stage product before the merge, and merge logic coordinates release so that cartons enter the main line at the right times and speeds.
Example Use Case
A fulfillment center operated three parallel packing lines that all needed to feed a single print-and-apply and sortation system. Initially, operators manually controlled flow, causing surges, backups, and uneven utilization. GlobalRoll implemented a Multi-Lane Merge Conveyor System with accumulation zones at the end of each pack line and a controlled merge module feeding the sorter. Lane speeds and release logic were configured so each line contributed evenly to the trunk conveyor while respecting downstream capacity. The result was smoother flow, reduced manual intervention, and improved sorter utilization.
Quality, Traceability & Maintenance
Multi-Lane Merge Conveyor Systems are built from GlobalRoll’s engineering-controlled templates for merge modules, infeed sections, and control packages. BOMs, routings, and wiring diagrams are standardized, ensuring every system meets defined performance and quality criteria.
Key components—such as drives, sensors, and merge control modules—are documented and can be tracked across builds. This consistency simplifies maintenance, expansion, and replication of successful merge designs in additional facilities or lines.
Maintenance is supported by modular construction and clear access to drives, rollers or belts, and sensors. Standardized diagnostics and control structures help maintenance teams isolate issues—whether in a particular lane, zone, or the merge itself—reducing downtime and speeding up recovery when problems occur.
Ready to Configure Your Multi-Lane Merge Conveyor System?
If you’re combining multiple lines into a single trunk conveyor or sorter, a properly designed merge system can be the difference between smooth flow and constant firefighting. GlobalRoll will work with your team to define lane counts, throughput targets, and priority rules, then configure a Multi-Lane Merge Conveyor System using proven modules and merge strategies.
Downloads & Resources
Use these documents to align operations, engineering, and IT teams around your merge strategy.
- Multi-Lane Merge Conveyor System Overview (PDF)
- Multi-Lane Merge Conveyor Technical Datasheet (PDF)
- Merge Layout & Control Planning Checklist (PDF)
- Maintenance & Troubleshooting Quick Guide (PDF)