Step 1: Define the Primary Purpose
What will your spiral conveyor be used for?
- Vertical Elevation: Move products between floors or levels.
- Product Accumulation: Temporarily buffer items before downstream processes.
- Cooling/Drying: Provide dwell time for temperature-sensitive products.
Example: A bakery may use a cooling spiral to allow pastries to rest before packaging.
Step 2: Evaluate Product Characteristics
- Size & Shape: Measure length, width, and height. Irregular shapes may need wider belts or tailored guides.
- Weight: Know both unit and cumulative loads—key to choosing the right motor and support frame.
- Fragility: Fragile goods like glass bottles need gentler incline angles and low-friction belts.
For plastic totes, modular plastic belts with anti-slip features are often ideal.
Step 3: Calculate Throughput Needs
- Determine required items per minute/hour.
- Influences spiral pitch, conveyor speed, and the number of tiers.
High-speed operations may benefit from tight-radius spirals with adjustable speed drives.
Step 4: Consider Space and Layout
- Assess floor space and ceiling height.
- Decide between upward or downward spirals based on product flow direction.
Tight warehouse layout? Go for a compact spiral model designed for small footprints.
Step 5: Factor in the Operating Environment
- Dry or Indoor Use: Coated steel may suffice.
- Wet, Humid, or Washdown Areas: Stainless steel construction and sealed electronics are essential.
Food plants often require full washdown compatibility and IP65+ rated motors.
Step 6: Choose the Appropriate Belt or Slat
- Plastic Modular Belts: For cartons, totes, and standard goods.
- Stainless Steel Slats: Best for corrosive or food-grade environments.
- Friction Slats or Rollers: Suitable for heavier products that need accumulation.
Step 7: Determine Accumulation Needs
- Continuous Flow: Ideal for high-throughput, uninterrupted lines.
- Accumulation Spirals: Handle stop-and-go operations without damaging products.
Packaging lines often benefit from accumulation spirals during line interruptions.
Step 8: Select the Right Drive System
- Use Variable Frequency Drives (VFDs) for precise speed control.
- Ensure compatibility with your automation system—add sensors or programmable logic controllers (PLCs) if needed.
Step 9: Prioritize Safety and Maintenance
- Include safety guards, emergency stops, and interlocks.
- Choose designs with easy maintenance access and self-lubricating parts.
Our conveyors at Synergy Automatics are designed with minimal downtime and ease of maintenance in mind.
Step 10: Weigh Budget Against ROI
Consider not just the initial cost, but the long-term value:
- Space-saving design
- Reduced labor and handling time
- Improved uptime and reliability
Well-selected spirals deliver ongoing efficiency and operational gains.
Industry-Wise Conveyor Recommendations
| Industry | Recommended Spiral Type |
|---|---|
| Food & Beverage | Stainless steel, washdown-safe, designed for hygiene |
| Warehousing | High-throughput spirals with accumulation features |
| Packaging | Compact, mid-speed spirals with gentle transitions |
| Bottling & Canning | Extended spirals for cooling or drying during transit |
| E-commerce | Tight-radius spirals for space-limited logistics operations |
Need Expert Advice?
Synergy Automatics is here to help.
Just tell us a few details, and we’ll recommend the best-fit conveyor for your operation:
- Industry (e.g., food processing, packaging, pharma, warehousing)
- Type of product being conveyed (e.g., cartons, bottles, trays, loose items)
- Required throughput (e.g., items per minute or hour)
- Application goal (e.g., elevation change, accumulation, cooling, drying)
- Space constraints (e.g., low ceilings, narrow floor footprint, tight turns)