When is it time to replace a Gravity Spiral Conveyor?
Gravity conveyors can be a simple way to move products between different elevations. But when product flow becomes unpredictable, jams become part of daily operations and employees regularly need to intervene, a simple solution can start creating bigger problems.
That was the situation at a large retailer using an older gravity skate wheel spiral to transport empty totes through its facility.
The solution wasn’t to add more equipment around the problem.
It was to take control of the product flow.
The challenge: when gravity becomes unpredictable
Gravity conveyors rely on exactly what their name suggests: gravity.
For certain applications, that can work well. But it also means there is less direct control over the speed and movement of individual products.
At this retailer’s facility, totes were accelerating unpredictably and crashing. The plastic-on-metal movement created significant noise, while employees regularly had to clear jams.
Three problems stood out:
Product damage
Totes accelerated unpredictably and crashed into each other.
High noise levels
The movement of plastic totes across the metal skate wheels created constant rattling.
Wasted labor
Employees had to repeatedly intervene to clear jams.
What appeared to be a relatively simple conveying solution had therefore become a source of disruption within the operation.
From gravity to controlled product flow
Apollo replaced the legacy gravity system with a Heavy Duty Spiral Conveyor, Model 1700-600-HD.
The biggest difference?
Control.
Instead of allowing gravity to determine how products travel down the spiral, a powered Spiral Conveyor provides controlled movement throughout the conveying process.
For this application, that meant creating a more predictable flow of totes between elevations.
What changed?
The new Spiral Conveyor addressed the key issues experienced with the old system.
Controlled flow and zero damage
Controlled conveying prevents totes from accelerating unpredictably as they travel between elevations.
For this retailer, the new system resulted in controlled product flow without the damage experienced with the previous gravity spiral.
A quieter operation
Removing the old skate wheel system also eliminated the constant plastic-on-metal rattling associated with the previous solution.
The result is a quieter and more reliable conveying process.
Less maintenance and intervention
A conveyor shouldn’t constantly demand attention from the people working around it.
With the previous system, employees regularly had to clear jams. The replacement was designed to provide a more reliable flow with low maintenance and no more unpredictable downtime.
That means employees can spend their time on the operation itself instead of repeatedly solving conveying problems.
Gravity Spiral vs. powered Spiral Conveyor: what’s the difference?
The most important difference isn’t simply whether one system has a motor.
It’s control over product flow.
A gravity spiral uses gravity to move products downward. A powered Spiral Conveyor actively conveys products along the belt, providing controlled movement between different elevations.
For operations handling totes, cartons or other unit loads, this can become particularly relevant when consistent product flow is important.
If an existing gravity system is causing frequent jams, uncontrolled acceleration, noise or damage, it may be worth considering whether gravity is still the right solution for the application.
Do you need to replace your entire conveying system?
Not necessarily.
This project is also a good example of how an existing material handling system can be improved by addressing one problematic part of the process.
Instead of redesigning the entire operation, the legacy gravity spiral was replaced with a powered Spiral Conveyor.
This type of targeted retrofit can be an interesting option for facilities where most of the existing conveyor system still performs well, but one section has become a bottleneck.
Sometimes optimizing your operation isn’t about replacing everything. It’s about fixing the part that’s holding everything else back.
When should you consider replacing a gravity conveyor?
There isn’t one answer for every facility, but there are several warning signs worth investigating.
If your gravity conveyor regularly causes jams, uncontrolled product speeds, product or tote damage, excessive noise or frequent manual intervention, the conveying method may no longer be the best fit for your operation.
The question then becomes:
How much time and productivity are you losing by keeping the existing system running?
A system that appears inexpensive because it is already installed can become costly when downtime, maintenance, damaged products and labor are taken into account.
Retrofit instead of working around the problem
Material handling systems often evolve over many years. Production requirements change, volumes increase and equipment that once worked well may eventually become a bottleneck.
It’s tempting to work around those problems.
But adding manual intervention or accepting recurring jams doesn’t solve the underlying issue.
A targeted conveyor retrofit can help create a more controlled and reliable product flow without necessarily redesigning the entire facility.
For this retailer, replacing an outdated gravity skate wheel spiral with an Apollo Heavy Duty Spiral Conveyor resulted in controlled flow, zero damage, quieter operation, low maintenance and an end to unpredictable downtime.
Frequently asked questions
What is the difference between a gravity spiral and a powered Spiral Conveyor?
A gravity spiral relies on gravity to move products downward, while a powered Spiral Conveyor actively conveys products between elevations. This provides greater control over product movement and speed.
Can a gravity spiral be replaced within an existing conveyor system?
Yes. This case demonstrates how an existing gravity spiral can be replaced with a powered Spiral Conveyor while addressing a specific problem within an existing material handling operation.
Why replace a gravity conveyor?
Replacement may be worth considering when an existing system causes recurring jams, unpredictable product movement, excessive noise, product damage or frequent manual intervention.
Is your gravity conveyor still doing its job?
If your team has learned to live with jams, noise or constant manual intervention, it may be worth looking at the problem differently.
Don’t work around an unreliable product flow. Take control of it.
Apollo Spiral Conveyors are designed to move products vertically within a compact footprint while providing a controlled, continuous product flow.