Gravity Conveyor Solutions for Order Fulfillment

Fulfillment and distribution centers are feeling the pinch. With faster delivery expectations, rising labor and energy costs, and SKU proliferation, even the most advanced facilities are under strain. The pressing challenge? Increase throughput without adding labor while making the most of every square foot.

In search of efficiency, many operators search high and low for the latest and greatest high-tech tools to speed up inventory movement. But sometimes, the smartest solution is also the simplest. Gravity conveyor systems offer a low-cost way to streamline product flow with minimal complexity.

These energy-free conveyors have held up as a go-to warehouse component for one simple reason: they work. Here’s how gravity conveyor solutions can help modern facilities meet today’s demands.

Rethinking Fulfillment With Lean, Gravity-Driven Flow

With the push for consistently higher throughput, more warehouse operators are turning to lean principles as a tried-and-true way to enhance efficiency. The lean focus on eliminating waste and streamlining workflows naturally supports this move toward faster fulfillment. 

Gravity conveyors offer an effective way to increase throughput and enhance overall productivity in order fulfillment environments. With nothing more than the force of gravity, these manual systems reduce the number of touches required to transport inventory throughout a facility. Workers spend less time walking, waiting, or double-handling items, which helps eliminate wasted motion, transportation, and time.

Rather than relying on costly powered equipment or extra labor to move goods from one area of the warehouse to the next, gravity conveyors support a continuous, streamlined flow of products and orders. This translates to faster cycle times, less worker fatigue, and better workplace ergonomics, all key tenets of lean best practices.

The Case for Gravity Conveyor Systems

Gravity conveyor solutions can be deployed anywhere products move within a fulfillment or distribution center. Think shipping lanes, packing stations, order picking zones — any location where you want to minimize worker movement while streamlining inventory flow. 

Wherever you deploy them, gravity conveyors bring a variety of benefits to your operation:

• Faster product flow: Gravity conveyors enable continuous movement of totes and cartons, reducing bottlenecks in your picking and shipping processes. They’re especially useful for high-velocity pick paths, where minor slowdowns can quickly turn into serious order backlogs.
• Better ergonomics: You can set gravity conveyor systems at the optimal height to reduce bending, lifting, and reaching for your workers. These systems maximize worker productivity while minimizing the risk of injury or fatigue, especially when combined with angled pick shelves and other dynamic storage solutions.
• Reduced downtime and maintenance: Unlike powered systems, gravity roller conveyors have no motors or controls that can fail at inopportune times. Complex moving parts are minimal, and the best options are built with durable galvanized steel for long-term performance.
  
  

The UNEX Difference: Engineered-to-Order Gravity Conveyor Solutions

When creating an order fulfillment warehouse plan, you need equipment that will move products seamlessly from stocking and picking to loading and shipping. That requires looking beyond one-size-fits-all solutions to build an inventory flow that works for you.

UNEX offers a versatile lineup of gravity conveyors, each designed to meet specific material handling needs. Here's a quick breakdown of the three core types:

Skatewheel (SW) Conveyors: Lightweight and highly maneuverable, UNEX Skatewheel conveyors are ideal for fast-moving, temporary setups where flexibility is key. Available in aluminum or galvanized steel frames across four widths, they excel at handling lightweight cartons and navigating turns, perfect for mobile pick lines or seasonal overflow zones.

JRS 1.38" Roller Conveyors: Offering more stability than skatewheels while remaining portable, JRS conveyors feature narrow-diameter steel rollers that are ideal for medium-duty use. They're a smart choice for facilities needing dependable, low-maintenance flow for cartons or totes that might not glide well on skatewheels.

MRS 1.9" Roller Conveyors: Built for heavy-duty, high-throughput operations, MRS conveyors feature large-diameter rollers and rugged steel frames. With five available widths, they’re engineered for permanent installations where medium to heavy-weight packages need to move reliably and safely day in and day out.

The choice of conveyor style is only the first step in building a warehouse conveyor system that fits your fulfillment or distribution center. From there, our team can help you select the optimal roller centers, widths, and support types to customize your conveyors for smoother product flow. 

Choose between aluminum and galvanized steel frames to match the durability and environmental needs of your facility. Galvanized steel for rugged is a good choice for high-use areas, and aluminum is ideal for lightweight, portable setups. Select from 5' or 10' conveyor lengths to accommodate your floor plan and application layout, and choose standard widths ranging from 12" to 24" to match the size and weight of your cartons or totes. With these options, you can tailor each conveyor run for ideal flow, minimal product friction, and maximum operational efficiency.

UNEX also offers a wide range of gravity conveyor accessories to help you customize your conveyor layout for maximum flow efficiency, safety, and flexibility. These add-ons are ideal for operations that require adaptable product movement, ergonomic improvements, or specialized routing.

Curves (45- or 90-degree): Guide product flow around corners or obstacles without interrupting movement. Great for compact or irregular floor plans where straight-line runs aren't possible.

Spurs: Allow products to merge or divert from one conveyor line to another at an angle. Ideal for sortation, packing lines, or creating branching lanes from a main conveyor run.

Gates: Provide a swing-up or lift-out section of conveyor to create a pedestrian access point. Useful in high-traffic areas where workers need to cross conveyor lines safely and frequently.

Package Stops: Prevent product from rolling off the conveyor at pick or pack stations. Help maintain order and control product positioning at transfer or processing points.

Ball Transfer Tables: Enable smooth, multi-directional movement of items at workstation intersections or inspection zones. Perfect for turning, repositioning, or sorting bulky or fragile packages without heavy lifting.

Guard Rail: Keep products securely on the track and prevent cartons from falling off the edges. These are especially useful for curved conveyors or uneven loads.

Each of these accessories adds functionality to your system and helps fine-tune your conveyor layout to match the pace, direction, and safety needs of your operation.

Gravity Conveyors in Action

When engineered to fit your fulfillment center, gravity conveyors can enhance efficiency and streamline workflows across your entire operation. In order picking, for instance, you can integrate gravity conveyors with carton flow solutions, such as SpanTrack Lane or Wheel Bed, to create a seamless flow from stocking to picking and fulfillment. 

Gravity conveyors are also ideal for packing stations. For example, installing gravity conveyors on or beside packing stations keeps parts and products flowing down the line and onto packaging or finishing areas, minimizing handoffs and unnecessary travel.

Returns processing areas present an excellent application for gravity conveyors, which can help streamline what is often a chaotic and variable workflow. Warehouses can create dedicated return lanes to sort, inspect, and route items more efficiently, even during peak return periods like post-holiday surges. Gravity flow helps reduce congestion at intake points, prevent bottlenecks, and maintain smoother throughput as returned inventory re-enters the system. 

Loading docks offer yet another opportunity to boost efficiency with gravity conveyors. At this critical transition point in the warehouse, gravity conveyors can help accelerate truck loading and unloading, reducing manual handling, minimizing bottlenecks, and keeping inventory moving in and out of the facility. Whether used as permanent fixtures or portable lines rolled into place as needed, gravity conveyors simplify product transfer between trailers and dock doors.

Tips for Integrating Gravity Conveyors in Your Operation

Whatever the application, it’s important to match your gravity conveyor solution to your operational needs. Start by choosing the right conveyor type for your inventory. Roller conveyors are ideal for handling heavier or uneven loads, while skatewheel conveyors offer smoother flow for lighter, uniform cartons, especially around curves or when rapid accumulation is needed.

Layout and design make a big difference in how well your gravity conveyors operate. Spurs, curves, and gates can help you navigate tight corners, merge product lanes, or create ergonomic pick access without disrupting flow. These accessories can help you design a gravity conveyor system that fits your space and allows for adjustments as your operation grows and changes.

For the best results, consider pairing your gravity conveyors with other UNEX solutions like SpanTrack, Roller Rack, or FlowCell. Together, these systems create seamless transitions between storage and picking, reduce walking and search time, and help maintain consistent product rotation. That gives you a leaner, faster, and more scalable warehouse ready to meet demand without driving up energy or labor costs.

A Smooth Path to Warehouse Efficiency

In modern fulfillment and distribution centers, every second counts. Gravity conveyors cut straight to the point: saving time without adding unnecessary complexity. By reducing manual touches, accelerating pick speeds, and making more efficient use of space, these passive systems deliver quick ROI while supporting broader warehouse optimization goals.

Gravity conveyors are just one component of a comprehensive system for increasing efficiency in order fulfillment. For peak optimization, you need a partner who understands the ins and outs of designing a complete setup for streamlined inventory movement. 

That’s where UNEX can help. Our team brings decades of experience in warehousing, order fulfillment, and storage optimization, and we’ve worked with operators of all kinds to design gravity conveyor solutions that fit lean principles and integrate with other systems. Contact us today, and we’ll help you turn gravity conveyors into a strategic advantage.