In today’s fast-paced manufacturing and packaging environments, maintaining efficient product flow is critical to maximizing throughput and minimizing downtime. Accumulation conveyors serve as essential buffer zones that ensure production lines continue to run smoothly even when bottlenecks occur. This comprehensive guide explores how strategic accumulation solutions can transform your operation’s efficiency and deliver significant return on investment.
What Are Accumulation Conveyors and Why Are They Critical?
Accumulation conveyors are specialized material handling systems designed to temporarily hold products in a controlled manner, creating a buffer between different production processes. Unlike standard conveyor belts that simply transport items from point A to point B, accumulation conveyors intelligently manage product flow to accommodate variations in upstream and downstream processes.
These systems become essential in scenarios where:
- Different production stages operate at varying speeds
- Equipment requires maintenance or experiences temporary stoppages
- Product inspection or quality control processes create bottlenecks
- Packaging operations need consistent product supply despite upstream fluctuations
- Line constraints threaten overall production efficiency
Key Benefits of Implementing Strategic Accumulation Equipment
Implementing the right accumulation system delivers substantial benefits to your production line:
1. Increased Throughput
Accumulation solutions can increase throughput by ensuring your constraint operations remain running even during temporary slowdowns elsewhere in the line. This productivity boost directly translates to improved production capacity and revenue potential.
2. Maximized Line Uptime
By keeping your constraint running, accumulation systems maximize overall line uptime and efficiency. This is particularly valuable for high-volume production facilities where every minute of downtime represents significant lost revenue.
3. Enhanced Product Protection
One of the most important features of modern accumulation systems is patented zero backpressure technology, which eliminates product and label damage during accumulation. This preservation of product integrity is crucial for delicate items, premium packaging, or products with precise labeling requirements.
4. Lower Maintenance Expenses
Well-designed accumulation systems minimize maintenance costs through simplified operation and reduced wear on components. This translates to lower total cost of ownership and fewer maintenance-related disruptions.
5. Optimized Space Utilization
Modern accumulation equipment is designed to shrink equipment footprint while maximizing buffering capacity. This space efficiency is invaluable in facilities where floor space comes at a premium.
6. Advanced Sustainability Advantages
Today’s accumulation solutions help meet sustainability initiatives with lower energy use during operation. This aligns with growing corporate environmental responsibility goals while simultaneously reducing operating costs.
7. Improved Workplace Environment
Advanced accumulation systems feature design elements that significantly reduce noise levels compared to traditional buffer solutions. This contributes to improved working conditions and a more comfortable production environment.
Specialized Accumulation Solutions for Diverse Applications
Dorner and Garvey offer several specialized accumulation systems designed to address specific operational requirements:
Small Parts Industrial Accumulation
For operations handling lightweight components, Dorner’s specialized small parts accumulation and recirculating tables offer an innovative solution. Engineered specifically to provide low-friction accumulation, these systems excel at recirculating assembly components in industrial manufacturing settings.
The BiFlo system implements a clever design with dual opposing conveyors that work in harmony to effectively recirculate products during wait times between production phases. The system’s specially designed diverting mechanisms guide products efficiently toward the central area, with manual adjustment options to redirect products to outfeeds when production demands change.
These intelligent accumulators enhance production synchronization by ensuring downstream operations receive a consistent, well-organized product flow. Our engineering team creates custom BiFlo configurations tailored to specific small parts handling requirements, enhancing both organizational efficiency and process reliability throughout manufacturing operations.
Large Capacity Accumulation
When your operation requires substantial buffering capabilities, Garvey’s large capacity accumulation tables deliver exceptional performance for even the most challenging products. These sophisticated systems maintain product integrity through minimal contact points and innovative zero-pressure technology.
The Garvey Infinity™ accumulation technology represents a significant advancement in high-speed product handling. These systems intelligently manage product flow to optimize efficiency across various functions, including lane separation, temporary buffering, and product organization. What sets these systems apart is their ability to maintain smooth, consistent operation even when running at peak capacity and maximum speed.
From a compliance standpoint, these advanced accumulators incorporate design features that align with the industry’s most stringent safety and sanitation protocols. Key engineering elements include optimized surfaces that minimize debris collection, reduced metal-to-metal contact areas that prevent contamination traps, and surfaces engineered for efficient cleaning procedures that satisfy FDA requirements.
- The system delivers multiple operational advantages:
- Advanced pressure management technology that protects product integrity
- Streamlined engineering that reduces maintenance complexity and operational costs
- Versatile lane management capabilities for production flexibility
- Engineering that minimizes surface friction and operational noise levels
Learn more about Dorner’s partnership with Garvey below.
Garvey Bi-Flo™ Accumulators
Garvey also offers their BiFlo™ Accumulation tables, designed for large-capacity applications and can be easily integrated into your production line. By utilizing opposing conveyor movement, these accumulation tables create efficient buffering areas with a small footprint to save on valuable space.
Garvey’s Bi-Flo™ Accumulators offer a wide range of benefits including:
- Increased Efficiency
- Multi-functional capabilities such as single file or lane divide
- Minimized maintenance cost
- Minimal energy use
- Reduced friction & noise
- And more
Pharmaceutical Vial & Bottle Accumulation
For pharmaceutical production environments, Garvey offers specialized accumulation and rotary table solutions engineered to meet the industry’s exacting standards. These systems optimize throughput while maintaining strict compliance with efficiency, safety, and sanitation requirements critical to pharmaceutical manufacturing.
The Garvey Infinity™ Rx Accumulator represents purpose-built technology for pharmaceutical applications, providing controlled, zero-pressure accumulation specifically engineered to solve the industry’s unique challenges. The system excels at handling notoriously unstable containers like vials, which traditional conveying methods often damage. The proprietary technology virtually eliminates product damage while maintaining exceptional production efficiency.
The pharmaceutical-specific design incorporates several key advantages:
- Reduced drive component count that simplifies maintenance and increases reliability
- Optimized energy consumption for sustainable operation
- Maximized production uptime through consistent product flow
- First-in-first-out handling that maintains product sequence integrity
- Flexible lane management for production adaptability
- Exceptional return on capital investment
- Proven performance metrics in pharmaceutical environments
- Dynamic flow division capabilities for production flexibility
Vertical Accumulation
When floor space constraints are a primary concern, Dorner’s vertical accumulation solutions provide an ideal alternative that maintains product sequencing while dramatically reducing footprint requirements.
The FlexMove Helix system represents an engineering breakthrough, combining compact design with flexible configuration options for efficient buffering in limited spaces. The innovative side roller chain technology reduces corner friction, enabling higher operational speeds and gentler product handling while maintaining adaptability to diverse application requirements.
This vertically-oriented system offers expanded configuration flexibility with customizable infeed and outfeed sections that extend beyond the main spiral. This intelligent design reduces the total number of required conveyors while simplifying system integration. The flexible positioning capabilities for both infeed and outfeed components allow placement at various heights and angles, creating seamless integration with existing production systems.
Common applications for this space-efficient solution include:
- Strategic product accumulation
- Production buffering requirements
- Product cooling processes
- Various specialized material handling needs
Advanced Accumulation Technology: What Sets Intelligent Motion Systems Apart
When evaluating accumulation solutions, several technological innovations separate industry-leading systems from basic offerings:
Pressureless Loop Technology
Backpressure can cause damage and collisions. Patented pressureless loop technology protects products by eliminating backpressure entirely.
High-Speed Outfeed Capability
On most accumulation systems, all lanes run at the same speed, causing products to become nested, which means they must be de-nested at the pickoff point. Our advanced accumulation tables feature a patented slowdown lane that de-nests products before they reach the pickoff point, reducing turbulence and allowing processors to increase their overall line speeds.
Industry-Compliant Design Elements
Quality accumulators are designed to meet the strictest industry regulations for safety and integrity. This includes reduction of areas where foreign materials can collect, minimized no metal-to-metal surfaces to eliminate entrapment, and easy to clean surfaces to meet FDA standards.
Expert Line Analysis
Before deciding on any solutions, a conveyance expert will meet with you to perform a free line analysis and find the best possible accumulation solution for your line.
Strategic Selection: Choosing the Right Accumulation Solution
Selecting the optimal accumulation system requires thorough evaluation of your specific production requirements. Consider these critical factors:
1. Product Characteristics
- Dimensions, shapes, and weight profiles
- Stability concerns (tendency to tip or fall)
- Fragility and sensitivity to contact forces
- Surface finish requirements (susceptibility to marring)
- Product format variations throughout production
2. Production Line Specifications
- Throughput requirements and line speeds
- Available physical space constraints
- Integration requirements with existing equipment
- Process variability between upstream and downstream operations
- Changeover frequency and flexibility needs
3. Industry-Specific Requirements
- Sanitation and cleaning protocols
- Regulatory compliance standards
- Material compatibility considerations
- Environmental conditions (temperature, humidity, etc.)
4. ROI and Performance Factors
- Current production bottlenecks
- Measured downtime costs
- Product damage or rejection rates
- Maintenance and labor expenses
- Throughput improvement potential
Better Together: CMCO’s Conveyance Solutions Group
As part of CMCO’s Conveyance Solutions Group, Dorner and Garvey work together with partner brands, montratec and Magnetek, to provide customers with innovative solutions to handling even the most unstable products. Together, weidentify specific needs and determine how to best increase your throughput. These accumulation solutions range from small-footprint bi-flo tables to complex distribution systems, and are custom engineered to solve industry challenges including pharmaceutical handling, beverage packaging, food processing, packaging, and more.
Industry-Specific Accumulation Applications
Accumulation systems play vital roles across diverse industries:
Food and Beverage Processing
In food and beverage production, accumulation systems create critical buffers between processes like filling, capping, labeling, and case packing. Dorner’s AquaGard and AquaPruf conveyor platforms provide sanitary solutions that comply with stringent industry requirements.
Pharmaceutical Manufacturing
Pharmaceutical operations require preciseand gentle handling of products like vials and bottles. Zero-pressure accumulation systems prevent damage while maintaining regulatory compliance. Dorner and Garvey’s pharmaceutical solutions address these specialized requirements.
Consumer Packaged Goods
CPG operations benefit from versatile accumulation systems that handle diverse product formats while maintaining line efficiency during changeovers and temporary stoppages.
E-Commerce Fulfillment
In distribution centers, strategic accumulation creates essential buffers between picking, sorting, and packing operations, maintaining consistent throughput despite variations in order processing times.
Automotive and Parts Manufacturing
In assembly operations, accumulation systems ensure continuous component supply to critical assembly stations, preventing costly production interruptions.
Measuring ROI: The Business Case for Accumulation Systems
The return on investment for strategic accumulation comes from multiple value streams:
- Enhanced Production Capacity: Throughput improvements that directly impact revenue potential.
- Minimized Downtime: Keeping constraint operations running continuously reduces costly stoppages.
- Product Quality Preservation: Zero-pressure technology significantly reduces product damage, waste, and rework.
- Maintenance Optimization: Simplified operation minimizes wear and maintenance requirements.
- Space Utilization Efficiency: Compact designs free valuable floor space for other value-adding operations.
Many operations find that quality accumulation systems offer payback periods counted in months, not years, making them one of the highest ROI improvements available for production lines.
ROI CALCULATOR: The Hidden Cost of Production Line Stoppages
| Line Value | 15-Minute Stoppage | 1-Hour Stoppage | 4-Hour Stoppage | Daily Impact of Accumulation Solution |
| $1,000/hr | $250 lost | $1,000 lost | $4,000 lost | +$750 gained |
| $5,000/hr | $1,250 lost | $5,000 lost | $20,000 lost | +$3,750 gained |
| $10,000/hr | $2,500 lost | $10,000 lost | $40,000 lost | +$7,500 gained |
| $25,000/hr | $6,250 lost | $25,000 lost | $100,000 lost | +$18,750 gained |
| $50,000/hr | $12,500 lost | $50,000 lost | $200,000 lost | +$37,500 gained |
Calculate Your ROI: Find your line’s hourly value (production value per hour), then see what a strategic accumulation solution could save you by preventing just three 15-minute stoppages per day.
The Bottom Line: The advanced accumulation systems from Dorner and Garvey pay for themselves within 3-6 months based on prevented downtime alone—not including additional benefits like reduced product damage, higher throughput rates, and improved quality control.
Calculate Your Custom ROI with Our Experts →
Implementation Best Practices
To maximize the value of your accumulation investment:
- Conduct a Comprehensive Line Analysis: Have an expert perform a free line analysis to identify the optimal configuration for your specific requirements.
- Focus on Constraint Operations: Prioritize accumulation before and after constraint operations to ensure these critical areas never stop due to upstream or downstream disruptions.
- Consider Future Flexibility: Select systems that can adapt to changing product formats and production requirements as your business evolves.
- Integrate Control Systems: Connect accumulation system controls with your production management systems for optimal line balancing and performance monitoring.
- Establish Performance Metrics: Implement clear KPIs to measure the impact of your accumulation solution on overall equipment effectiveness (OEE).
Strategic Accumulation as a Competitive Advantage
In today’s demanding manufacturing environment, strategic accumulation represents far more than simple product buffering. By implementing advanced accumulation technology, manufacturers can unlock significant improvements in throughput, uptime, product quality, and operational efficiency.
Dorner’s comprehensive range of accumulation solutions, enhanced through the Conveyance Solutions Group, provides options for virtually any production scenario. From small parts handling to high-volume pharmaceutical applications, these systems deliver measurable performance improvements backed by decades of engineering expertise.
To explore how advanced accumulation solutions can optimize your specific operation, contact Dorner for a personalized consultation including a comprehensive line analysis. Our team of experts will help identify the ideal configuration to address your unique challenges and maximize your production efficiency.
FAQs
What distinguishes transportation conveyors from accumulation conveyors?
Transportation conveyors simply move products from one point to another, while accumulation conveyors are designed to temporarily hold products in a controlled manner, creating buffers between different production processes that accommodate speed variations and temporary stoppages.
How do zero-pressure accumulation systems protect products?
Zero-pressure accumulation systems utilize specialized technology to eliminate contact pressure between products during accumulation. This prevents damage to packaging, labels, and the products themselves while allowing dense accumulation without product-to-product pressure.
What types of products can effectively be handled by modern accumulation systems?
Today’s advanced accumulation systems can handle an extensive range of products, from stable containers to highly unstable items like vials, pouches, and irregularly shaped packages. Specialized systems are available for nearly any product characteristic or stability profile.
How do vertical accumulation systems maximize space efficiency?
Vertical solutions like Dorner’s FlexMove Helix utilize vertical space rather than valuable floor area, maintaining product sequence while dramatically reducing footprint compared to traditional horizontal accumulation systems.
How does accumulation directly impact Overall Equipment Effectiveness (OEE)?
Accumulation systems improve OEE by addressing all three components: availability (reducing downtime), performance (increasing throughput), and quality (minimizing product damage). By ensuring constraint operations run continuously despite temporary stoppages elsewhere, they directly enhance key performance metrics.
What industries benefit most from zero-pressure accumulation technology?
Industries handling delicate, unstable, or high-value products see the greatest benefit from zero-pressure technology. This includes pharmaceuticals (vials, syringes, bottles), food and beverage (glass containers, flexible pouches), consumer products (premium packaging), and electronics manufacturing.
How do accumulation systems adapt to product changeovers?
Advanced accumulation systems feature adjustable guides, modular designs, and quick-change components that minimize changeover time between different product formats, supporting flexible manufacturing environments with diverse product portfolios.
