Powered Roller Transfer Conveyor System
High-torque, powered roller transfers for controlled product movement and line transitions.
The Powered Roller Transfer Conveyor System from GlobalRoll is engineered for applications where products must move between conveyor lines, change direction, or transition between equipment with positive control. Using powered rollers, driven transfer sections, and precisely designed frames, this system delivers reliable, repeatable transfers for cartons, totes, and other handled loads—especially where gravity or passive transfers aren’t enough.
Applications & Use Cases
Powered roller transfers are ideal anywhere you need active control over how product moves from one conveyor to another.
- Transferring cartons or totes between perpendicular conveyor lines
- Feeding or discharging products at workstations, print-and-apply stations, or inspection cells
- Controlled entry and exit points on sortation lines and accumulation zones
- Changing direction where gravity or passive roller transfers are unreliable
- Transitioning between conveyors running at different speeds or elevations
- Integrating with scanners, labelers, or weigh scales where stable product control is required
System Overview
GlobalRoll’s Powered Roller Transfer Conveyor System uses high-torque drive rollers and engineered transfer sections to move products smoothly between conveyors. Transfers can be straight, 90°, or custom angles, with roller spacing and drive power configured to handle your product size, weight, and line speed without stalling or skewing.
This product family is defined in GlobalRoll’s templates as standardized transfer modules with specific roller sets, drive packages, frames, and sensor options. We configure these templates to match your layout and operational requirements, creating powered transfer points that integrate cleanly with existing conveyors and automation while maintaining full traceability of critical components.
Key Features & Benefits
Features
- Powered roller transfer modules for positive, controlled product movement
- Configurable transfer geometry (straight, 90°, or custom angles)
- High-torque drive rollers sized for your product weight and friction requirements
- Precisely spaced rollers for stable product support across transfer gaps
- Integration-ready frames for mounting between or alongside existing conveyors
- Options for integrated sensors to detect product presence and verify transfer
- Standardized module designs for consistent performance across multiple lines
Benefits
- Reliable transfers: Reduces stalls, skewing, and jams at key line transitions.
- Better control: Maintains product orientation and spacing through handoff points.
- Higher throughput: Keeps product moving smoothly between conveyors and equipment.
- Flexibility: Fits diverse layouts, including perpendicular or angled connections.
- Repeatability: Template-based designs make it easier to replicate successful transfers in other areas.
- Maintainability: Standardized components and documentation simplify service and spare parts planning.
Configuration Options
Each Powered Roller Transfer Conveyor System is configured using GlobalRoll’s standardized transfer modules, then tailored to your line layout and product requirements.
Mechanical & Dimensional Options
- Conveyor Width: Transfer width sized to your cartons or totes with appropriate overhang and clearance
- Transfer Length: Short or extended transfer sections depending on product stability and layout needs
- Roller Diameter & Type: Multiple roller diameters and surfaces available for different weight and friction needs
- Roller Centers: Configurable spacing to support small, medium, or large products without tipping or bridging
- Frame & Mounting: Engineered frames designed to mount between existing conveyors, at right angles, or in custom positions
- Elevation Fit: Configured to match upstream and downstream conveyor heights or to bridge minor height differences
Drive, Control & Sensor Options
- Drive Packages: High-torque roller drives or external drives sized for product load and required acceleration
- Speed Control: Fixed speed or variable-speed transfers to match adjacent conveyor speeds
- Direction Control: Forward-only or reversible operation depending on transfer direction needs
- Sensors: Photo-eyes or presence sensors at transfer entry/exit to verify product movement and detect jams
- Control Integration: PLC-ready with I/O points for start/stop, speed, and status feedback; can be tied into existing line controls
Available Accessories
- Side guides and guardrails to maintain product alignment at transfer points
- Skirts or transition plates to minimize gaps between conveyors
- Supports and brackets to tie transfers structurally into existing conveyor frames
- Local operator controls for jogging or manual transfer control (where needed)
- Optional mounting for scanners, labelers, or inspection devices near transfers
Technical Highlights
Technical specs are configured for each application, but Powered Roller Transfer Conveyor Systems typically include:
- Load Capacity: Engineered based on maximum product weight and desired acceleration through the transfer
- Roller Diameter & Centers: Selected to balance load capacity, support, and smooth movement across the transfer
- Transfer Geometry: Configurable angles (commonly 90°) for perpendicular or near-perpendicular transfers
- Line Speeds: Tuned to match upstream and downstream conveying speeds and desired throughput
- Environment: Suitable for typical warehouse, distribution, and production environments; special variants available as needed
- Power: Industrial power options matched to drive and control requirements for transfer modules
Typical Layouts & Use Cases
A typical Powered Roller Transfer Conveyor layout may include main trunk conveyors with powered transfers feeding perpendicular pack lines, workstations, or separate processing areas. Transfers can also be positioned at key points where product must move between accumulation zones and sorters, or between print-and-apply stations and outbound lines, maintaining control over product orientation and spacing.
Example Use Case
A distribution facility needed to feed cartons from a main conveyor into multiple manual rework stations and then back onto the main line. GlobalRoll supplied Powered Roller Transfer Conveyor modules that diverted product at 90° into each station and then returned completed cartons to the trunk conveyor. The powered transfers maintained consistent product movement, reduced manual pushing across passive transfers, and improved flow around the rework loop.
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)