Zero-Pressure Accumulation Conveyor System
Gentle, controlled product flow with no back-pressure and no collisions.
The Zero-Pressure Accumulation Conveyor System from GlobalRoll is designed for applications where cartons, totes, or cases must queue without touching. Using intelligently controlled zones, photo-eyes, and drive modules, this system maintains gaps between products, prevents pileups, and keeps downstream processes running smoothly—all without constant operator intervention.
Applications & Use Cases
Zero-pressure accumulation is ideal anywhere you need controlled buffering and gentle handling.
- Buffering zones upstream of palletizers, sorters, and print-and-apply systems
- Queues feeding case sealers, stretch wrappers, and weigh stations
- Merge points where multiple lines feed a single trunk conveyor
- Accumulation before manual or automated picking, packing, or inspection
- Product staging at shipping lanes and lane-divert systems
- Any operation where contact between products can cause damage or jams
System Overview
The Zero-Pressure Accumulation Conveyor System is built around individually controlled zones. Each zone uses sensors to detect product presence and logic to start or stop its drive, maintaining a controlled gap between items. When downstream zones are full, upstream zones progressively stop, holding products in place without back-pressure.
GlobalRoll’s accumulation conveyors are defined as product templates with standardized zone modules, roller options, drives, sensors, control logic, and wiring harnesses. We configure these templates to match your carton sizes, weights, speeds, and layout, giving you a proven accumulation design tailored to your operation without starting from a blank sheet.
Key Features & Benefits
Features
- Individually controlled accumulation zones with integrated sensors
- True zero-pressure operation—products do not touch while queued
- Configurable zone lengths and counts to match product size and buffer needs
- Roller or belt-driven modules sized for cartons, totes, or similar loads
- Standardized controls architecture for zone logic and communication
- Integration-ready for upstream and downstream equipment (palletizers, wrappers, sorters, etc.)
- Optional manual release, priority release, or slug release modes depending on application
Benefits
- Product protection: Prevents product scuffing, crushing, or label damage caused by back-pressure.
- Smoother operations: Buffers absorb process variation and keep downstream equipment fed consistently.
- Fewer jams: Controlled flow reduces sudden surges and misalignments at transfers or merges.
- Improved ergonomics: Operators spend less time manually managing surges and blockages.
- Scalability: Zone-based design makes it easier to extend, add, or reconfigure accumulation as needs grow.
- Easier troubleshooting: Standardized modules and controls simplify diagnostics and maintenance.
Configuration Options
We configure Zero-Pressure Accumulation Conveyor Systems based on your product dimensions, required buffer capacity, and line speeds.
Mechanical & Dimensional Options
- Zone Length: Configurable zone lengths based on typical and maximum product length
- Number of Zones: Determined by required buffer capacity and available footprint
- Conveyor Width: Sized to your carton, tote, or case dimensions with appropriate side clearance
- Roller Specifications: Diameter, material, and bearing options tuned to your load and duty cycle
- Frame & Supports: Heavy-duty frames with fixed or adjustable supports to match your floor and elevation needs
- Conveyed Product Types: Cartons, totes, trays, or similar handled loads; special configurations available on request
Drive, Control & Zone Options
- Drive Types: Motor-driven rollers (MDR) or externally driven rollers depending on application
- Zone Control: Standard zone logic for zero-pressure, with options for minimum-pressure or continuous modes if needed
- Sensor Types: Photo-eyes and presence sensors integrated into each zone for precise detection
- Release Modes: First-in-first-out, priority release, slug release, or custom sequencing as required
- Control Integration: PLC integration, networked drives, and I/O designed to work with your existing control architecture
Available Accessories
- Side guides and guardrails to maintain alignment
- Merge modules and diverting sections to connect multiple lines
- Workstation infeed/outfeed sections tied into accumulation zones
- Transfer sections to and from sorters, palletizers, and wrappers
- Status indicators, HMI panels, and operator controls for manual override and diagnostics
Technical Highlights
Specific ratings depend on your configuration, but Zero-Pressure Accumulation Conveyor Systems typically feature:
- Load Capacity: Engineered for your maximum carton/tote weight per zone with appropriate safety margin
- Zone Count: From a handful of zones to extended-zone systems spanning entire lines or mezzanines
- Line Speed: Configured to match upstream production rates and downstream equipment cycle times
- Environment: Suitable for dry warehouse, distribution, and production environments; special builds available for other conditions
- Power: Designed around industrial power standards and control system preferences
- Materials: Heavy-duty steel frames, engineered rollers, and reliable sensor/drive components sized for continuous-duty use
Typical Layouts & Use Cases
A typical Zero-Pressure Accumulation Conveyor layout places a series of zones before critical equipment—such as palletizers, sealers, or sorters—to ensure a predictable, controlled flow of cartons. Accumulation lines can run parallel to packing stations, feeding a main trunk conveyor, or sit upstream of automated equipment to absorb process variations and prevent machine starvation or blocking.
Example Use Case
A distribution operation needed to feed cartons into an automated print-and-apply and sortation system, but incoming flow from packing stations was highly variable. GlobalRoll configured a Zero-Pressure Accumulation Conveyor with multiple zones before the print-and-apply station and another bank of zones before the sorter. The system ensured a consistent flow into both machines, eliminated back-pressure damage to labeled cartons, and reduced manual intervention at peak times.
Quality, Traceability & Maintenance
Zero-Pressure Accumulation Conveyor Systems are built using GlobalRoll’s engineering-controlled templates for zone modules, rollers, drives, and controls. BOMs and routings are standardized, so each zone is built and wired according to defined specifications and quality criteria.
Key components—such as motor-driven rollers, sensors, and control modules—can be documented and tracked, giving you a clear bill of material and a consistent parts strategy across your accumulation lines. When you expand or modify the system, the same module definitions can be reused.
Maintenance is simplified by modular design. Zone modules are designed for quick access to rollers, drives, and sensors, and standardized parts reduce the variety of spares you need to keep on hand. Diagnostics through your control system—or local indicators—help maintenance teams quickly pinpoint issues in a specific zone instead of chasing problems across the entire line.
Ready to Configure Your Zero-Pressure Accumulation System?
If you’re dealing with product damage, inconsistent flow, or constant micro-adjustments around key equipment, a properly designed zero-pressure accumulation system can change how your line runs. GlobalRoll will work with you to define product sizes, buffer requirements, and control preferences, then configure a system using proven accumulation modules.
Downloads & Resources
Use these references to align engineering, operations, and maintenance teams around your accumulation strategy.
- Zero-Pressure Accumulation Conveyor System Overview (PDF)
- Zero-Pressure Accumulation Technical Datasheet (PDF)
- Accumulation Zone Layout Planning Checklist (PDF)
- Maintenance & Troubleshooting Quick Guide (PDF)