Boost Efficiency with a Powered Roller Conveyor

Why a Powered Roller Conveyor Could Be the Missing Link in Your Automation Strategy

In high-throughput environments like eCommerce, logistics, and distribution, a powered roller conveyor offers a smart, scalable way to move cartons, totes, and trays with minimal manual handling. Whether you’re dealing with increased order volumes or labour shortages, these conveyor systems deliver a reliable and flexible solution to automate your internal transport processes.

Is a Powered Roller Conveyor Right for You?

Ask yourself:

• Are you struggling to retain pickers or packers?
• Do you handle more than 6 pickers at once?
• Could your space be used more efficiently?

If you answered yes to any of these, it’s time to consider automation.

How Powered Roller Conveyors Work

The Basics of Powered Rollers

Powered roller conveyors use motorised rollers to move loads along a track. Unlike gravity-fed systems, powered rollers provide precise control of movement—ideal for accumulation zones, sortation, or where speed and timing matter.

They're especially effective for:

• Order fulfilment centres
• Parcel and tote handling
• Integration with automated picking and packing stations

At Diamond Phoenix, we use industry-leading components from Conveyor Units to deliver systems that are built for long-term performance.

Key Benefits of Using Powered Roller Conveyor Systems

Reduce Labour Costs and Manual Handling

Many of our clients are facing labour challenges: difficulty hiring, rising costs, and the need to scale faster. A powered roller conveyor system addresses these issues head-on, reducing dependency on manual labour while speeding up throughput.

Improve Flow and Accuracy

These systems maintain a smooth flow of materials across multiple processes—from picking to packing, sorting, and shipping. With options for zoning and accumulation, you can avoid bottlenecks and improve order accuracy.

Powered Roller Conveyors in Action

One recent project involved a national 3PL provider handling 10,000+ orders daily. By integrating powered roller conveyors with automated packing benches and a put-away system, they reduced manual touchpoints by over 60%—all while improving pick rate accuracy and floor space utilisation.

Explore More:

Powered roller conveyors are an ideal solution for automating the movement of cartons, totes, and other unit loads across a facility. They provide smooth, controlled transport, which reduces the need for manual handling and improves workplace safety. These conveyors are highly versatile and can be configured to suit a wide range of layouts, including accumulation zones, merges, diverts, and sortation points—perfect for busy eCommerce, logistics, and fulfilment environments. By increasing speed and accuracy in material handling, powered roller conveyors help businesses boost productivity, reduce labour costs, and handle higher order volumes with ease.

• Learn more about our carton conveyor systems
• See how we help clients in fulfilment and eCommerce

Need help designing the right solution? Contact us today to talk with Keith or Matt.