Cost-Benefit Analysis of Automated vs. Manual Conveyor Systems

Conveyor systems are one of the most popular material handling processes, and they can be found in distribution centers, warehouses, manufacturing plants, mines, and other industrial environments. Primarily responsible for moving products and goods from one point to another, they help streamline movement, reduce manual labor, and increase overall efficiencies, thus offering a competitive advantage.

But there are many types of conveyor systems to choose from – and it’s important to select the best one for your environment to realize the full benefits of these material handling solutions. In this post, we’ll discuss two popular types of conveyor systems: automated and manual. Read on for more information.

Overview of Automated Conveyor Systems

Automated conveyor systems are just what they sound like – conveyors that operate automatically without much, or any, need for human intervention. They work by using a combination of sensors and motors, which work to detect product flow and accelerate and decelerate the speed of the conveyor belt, helping to improve productivity, enhance safety, and decrease labor costs. Automated systems can help improve customer satisfaction, productivity, enhance workplace safety, and decrease labor costs by reducing human error.

So, what types of industries can benefit from automation and automated conveyors? Literally any and every industry. If you’re serious about enhancing your business objectives and operational efficiency, then you should seriously consider working with an automated conveyor. While the initial investment and setup costs are more than what you’d spend on a manual conveyor, the productivity benefits and labor savings will likely make up for it.

Overview of Manual Conveyor Systems

Manual conveyor systems commonly rely on roller conveyors, hoists, tracks, and other mechanisms to move products from one part of the facility to another. A common type of manual conveyor is an overhead conveyor, where products are loaded and moved via elevated rails.

Manual conveyor systems have low upfront costs, but ongoing labor requirements are required for effective operation.

Cost Analysis: Upfront Investment vs. Long-Term Savings

Conveyors can cost anywhere from tens of thousands of dollars to hundreds of thousands of dollars – and automated conveyors tend to be on the higher end of this price range due to their more complex nature and advanced features. However, they have fewer operational expenses. Manual conveyors, conversely, have lower upfront costs, but higher operational costs. Additionally, there is also the risk of injury from manual material handling. 

Generally speaking, automated conveyors present a better long-term value proposition when you consider benefits such as reduced labor requirements and increased operational efficiency.

Operational Efficiency and Productivity Comparisons

Automated conveyors tend to be faster, more productive, and more consistent – three key advantages. However, their automated nature often means more regular maintenance is required to ensure the conveyor continues to operate to its full potential.

Labor Considerations: Workforce Impact and Safety

Automated conveyors are the safer option of the two conveyors because there’s less of a need for manual labor with such systems. While you may think there’s a greater potential for job displacement with automated systems, they can also result in a more skilled workforce as employees train on how to operate such systems.

ROI on Automation: When Does It Make Sense?

Does automation make sense for your business? There are various factors that you’ll want to weigh to gauge ROI. These include:

• Initial costs
• Operational costs
• Labor savings
• Scalability
• Production volume

By factoring in these variables, you should have a more clear timeline for when you can expect to break even with this investment.

Choosing the Right System for Your Business

Whether you select an automated or manual conveyor for your business depends on a variety of factors, including your budget, scalability of such solutions and your industry needs. In some cases, it might make sense to take a hybrid approach to your conveyor system, where there’s a combination of automated and manual solutions.

Final Recommendations

If you want to increase productivity, an automated solution is right for your business. But if you’re still a small business that’s looking to increase market share before scaling up, you may benefit more from a manual solution. To learn more about automated and manual conveyor systems, and to browse our selection, contact A-Lined today.