Reducing Operational Costs with ARB Conveyors in Distribution Centers

Operational costs in distribution centers often rise due to frequent maintenance, manual sorting, and poor space use. These issues lead to delays and long-term expenses. Choosing the right conveying solution helps address these problems directly.

ARB conveyors, a type of custom automation conveyor, are well-suited for distribution environments where flexibility, precision, and reliability are necessary. 

These conveyors use Activated Roller Belt (ARB) technology to manage merging, sorting, turning, and alignment. Fewer moving parts and reduced mechanical strain help lower maintenance needs and reduce reliance on manual handling.

Cost-Saving Features of ARB Technology Conveyors

Labour and maintenance account for a large portion of operating budgets in distribution environments. ARB technology conveyors help reduce both.

• Lower maintenance needs: With fewer belts, motors, and contact points, ARB conveyors experience less mechanical wear. This reduces service frequency, cuts down on unexpected breakdowns, and extends the system’s lifespan.
• Reduced labour involvement: Built-in features such as passive rollers and directional control allow products to move, sort, and align without manual input. This decreases the number of staff required on the floor, cutting labour costs and reducing the risk of handling errors.
• Compact layouts: The design supports turning, merging, and transferring on a single platform. This allows operations to run multiple processes in confined spaces, helping businesses avoid expensive layout changes or facility expansions.
• Energy use reduction: The low-friction design reduces motor load and energy consumption during continuous use. Over time, this leads to noticeable savings on power bills and lowers overall operating costs.

These systems stay functional and cost-effective over time by focusing on dependable mechanics.

ROI Analysis: Long-Term Savings and Productivity Gains

Distribution centers that adopt ARB conveyors often see results within the first year. These systems simplify workflows, shorten order cycle times, and reduce staff dependency during peak hours.

Over 24 months, most savings emerge in these areas:

• Fewer emergency repairs or unplanned shutdowns: With fewer moving parts and lower wear, breakdowns are less frequent. This reduces repair costs and keeps production schedules on track.
• Less reliance on short-term labour or temporary hires: Built-in handling and sorting functions reduce the need to scale up headcount during busy periods.
• Improved floor productivity through uninterrupted movement: Fewer halts and more controlled flow allow for easier transitions between sorting, packing, and staging.
• Lower training costs: With fewer operators required and simpler controls, training time and resources are minimized, especially valuable when onboarding new staff.
• Longer equipment life: The modular design and durable components of ARB technology conveyors reduce the need for early replacements. Their long lifespan also reduces capital spending on future replacements or upgrades. For growing facilities, this stability allows for expansion planning without revisiting the layout foundations.

Custom-Built Conveyors as a Strategic Investment

Reducing operational costs requires choosing systems that align with current output needs and future plans. That’s why distribution centers are investing in custom-built conveyors that match their product types, order volumes, and available space.

CONOVEY builds every system based on a clear understanding of site requirements. The approach combines practical design with real-world performance, from small-scale sortation lines to large-scale handling setups.

To learn how our custom-built conveyors can reduce operating costs in distribution centers, contact CONOVEY today!