Conveyor systems are the beating heart of any efficient material handling operation. Whether you’re expanding your facility, replacing outdated equipment, or starting fresh, choosing the right conveyor system isn’t just a matter of logistics—it’s a decision that can impact your throughput, labor efficiency, safety, and long-term profitability.
With the stakes this high, it’s essential to take a strategic, informed approach.
At Maybury, we’ve spent decades helping organizations—from growing warehouses to complex manufacturing operations—design and implement conveyor solutions that fit like a glove. In this guide, we’ll walk you through the seven critical factors to consider when selecting a conveyor system for your facility.
Understanding the Flow of Your Products
Every facility handles a unique mix of materials. Are you moving fragile electronics or heavy pallets? Small cartons or bulk grain? Before you even begin evaluating conveyor options, take a close look at your product characteristics.
Consider size, weight, shape, and material. Even surface texture matters—some items require friction for control, while others move better on low-resistance belts. You’ll also want to identify whether your products need to remain oriented in a specific way or undergo scanning, weighing, or labeling along the line.
A misaligned conveyor system can slow operations or damage your product. On the other hand, a well-matched system can enhance flow, reduce touchpoints, and boost accuracy. Maybury’s material handling experts can help assess your specific load requirements and recommend solutions that match.
Factoring in Your Facility’s Layout
No two facilities are alike—and neither are their challenges. Some operations need to move product across multiple levels. Others must work around narrow aisles, structural supports, or existing equipment. These constraints play a big role in choosing the ideal conveyor system.
Vertical lifts or spiral conveyors may be the right fit for tight vertical spaces, while modular belt conveyors can snake through tight corners without compromising flow. Overhead systems are great for freeing up floor space, especially in facilities with high ceilings.
Before making any decisions, walk your floor. Measure. Sketch out your workflow. Better yet—let Maybury do it for you. Our design team can map out your space and show you exactly how a new conveyor system can optimize it.
Automatic conveyor system with several lines in two levels and conveyor lift in warehouse E-commerce
Planning for Throughput and Peak Demand
It’s not just about how much product you move—it’s about how fast, and how often.
An efficient conveyor system should keep pace with both your average workload and your busiest peak. Systems that are too small create bottlenecks. Ones that are too large waste energy and space.
Think ahead. How will your business grow in the next 3–5 years? Are you planning to add automation or increase production shifts? A scalable conveyor system—one that can grow with you—will help you avoid costly upgrades down the road.
At Maybury, we work with clients to project their future needs and match systems that deliver consistent performance without overbuilding.
Choosing the Right Conveyor Technology
Conveyor systems come in many forms, each with its strengths. Belt conveyors are ideal for lightweight, fragile items that need a smooth ride. Roller conveyors handle heavier loads and can allow for accumulation. Overhead conveyors are ideal for freeing up valuable floor space, while screw or pneumatic conveyors serve bulk or powdered materials.
The right choice depends on your product type, facility layout, industry standards, and operational goals.
Not sure where to start? We’ve helped clients across industries—retail, automotive, pharmaceuticals, food and beverage, and beyond—find the right fit. Reach out to our team at Maybury to learn more and get your questions answered.
Ensuring Safety, Compliance, and Ergonomics
A conveyor system should do more than move products—it should protect your people. Look for features like guarded pinch points, emergency stop buttons, controlled start/stop zones, and ergonomic loading heights. Not only do these features reduce injury risk, but they also keep your operation in line with OSHA and ANSI standards.
Safety should be baked into your system—not added later as an afterthought. At Maybury, we incorporate safety into every design, helping you create a workplace that keeps productivity up and liability down.
Need a compliance check on your current setup? We’re happy to help. Contact us to book a conveyor safety inspection.
Integrating with Software, Automation, and Future Tech
Conveyor systems are smarter than ever. With proper integration, they can sync with your warehouse management system (WMS), enterprise resource planning (ERP) software, barcode scanners, vision systems, and even robotics.
This connectivity enables real-time tracking, predictive maintenance, and data-driven decision-making.
Whether you’re ready to leap into full automation or want to keep things semi-manual with room to grow, your conveyor should support your future—not hold it back.
Maybury offers full integration services, including PLC programming and IoT connectivity.
Conveyor Belt in a modern production line.
Looking Beyond Price: Total Cost of Ownership
It’s tempting to focus on the purchase price—but the smartest companies look deeper. A conveyor system’s real cost includes installation, energy use, maintenance, downtime, and the ROI it delivers over its lifespan.
A cheaper system that breaks down more often or lacks upgrade options can cost far more over time than a slightly higher-priced system that runs smoothly for a decade.
Maybury helps you evaluate systems not just by cost—but by value. We’ll provide a clear breakdown of total cost of ownership and help you find the balance between performance and budget.
Let’s Build Your Perfect Conveyor Solution
Choosing the right conveyor system is a pivotal step in optimizing your facility’s performance. With thoughtful planning and expert guidance, it can become a game-changing asset—one that reduces costs, increases safety, and scales as you grow.
At Maybury, we don’t believe in one-size-fits-all. We believe in right-fit solutions built around your workflow, your goals, and your people. We’re here to help you move smarter—every step of the way. Contact us today!