Engineered Solutions

Vacuum Belt Conveyors

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Vacuum Conveyors

When your products or components are small, lightweight and moving at a steady speed, you need a transfer solution that will keep things on track, literally. Vacuum conveyors use suction to hold items of all sizes in place as they move along, up and down the belt.

Vacuum Belt Conveyors

Among all of your conveying options, vacuum belt conveyors are ideal when you’re working with small, flat parts and other lightweight, thin materials. Like all Dorner conveyor solutions, our vacuum belt conveyors come in a variety of configurations, enabling you to optimize your physical space while keeping your production and budget needs in mind. Some models handle varying elevations, enabling you to fit them into tight spaces. Additionally, a range of add-ons and accessories help meet your product and process needs. See vacuum conveyor belt technology in action in this video showing small packaged goods running on the underside of a conveyor.

How Do Vacuum Conveyors Work?

Vacuum conveyors work by creating suction that keeps items flat on the belt surface. For example, a vacuum conveyor belt could prevent sheets of paper, plastic parts, cardboard, leaflets, small pouches, or empty plastic packaging from flying away as they move down the line. This suction power is created by an internal vacuum pump that pulls air flows through perforations within the belt. This creates a seal, keeping items intact. Each vacuum conveyor is custom designed based on the customer’s application and product. Dorner’s engineers work with our customers to figure out the proper belt and hole spacing, pattern and size. Vacuum conveyors use a custom bed plate with a vacuum chamber to focus the suction on the proper place. Ports are custom-drilled into the conveyor frame for the vacuum. The number of ports drilled depends on our customers’ needs. There is no vacuum on the conveyor tails. The suction prevents any slipping or sliding of the product while the product can still be easily lifted away from the belt. Dorner can provide the blower assembly or our customers can provide their own.

Vacuum Conveyor Applications

Vacuum conveyors are seen in a variety of industries, from health care and pharmaceuticals to manufacturing and metalworking. Within these and other industries, vacuum conveyors are useful for many specific applications, including: 
  • Inspection
  • Precision part movement
  • Small part handling and positioning
  • Work holding 
  • Part and package infeed and outfeed
  • Printing
  • Automated assembly
  • Manual assembly

Custom Vacuum Conveyors

Sometimes an out-of-the-box solution isn’t enough for your unique products, applications, or business goals. A leading vacuum conveyor manufacturer, Dorner is also home to our seasoned Engineered Solutions Group. This full-service team can modify a standard solution to meet your needs, or can collaborate with you to build a completely custom system. We work with you from concept to completion, including a full needs analysis, CAD modeling, mechanical design and other aspects of the custom vacuum conveyor design process.  

Vacuum Conveyor Design

Dorner’s vacuum conveyor design experts find solutions to meet each customer’s exact part-moving needs. We combine our vacuum belt conveyors with expert control technology to ensure precision part location, whether it’s fluting paper, empty plastic bottles or injection-molded parts. Our custom vacuum conveyors are also built to fit into a variety of spaces, and they can be integrated with a wide range of accessories.

Vacuum Conveyor Belt Systems

Dorner offers a variety of durable, high-quality vacuum conveyor belt systems for our 2200 and 3200 series.

2200 Series Vacuum Conveyor

Dorner’s 2200 Series conveyors work best for small to medium part handling. These systems can handle loads up to 120 pounds and speeds up to 400 feet per minute. This specs and capabilities of the 2200 vacuum belt conveyor systems fit the needs of the pharmaceutical and medical industries well.

3200 Series Vacuum Conveyor 

Our 3200 Series conveyors line is ideal for long runs, high speeds and heavier loads. Suitable applications include part handling and accumulation, processing and packaging, automation and assembly. This system has flexible layout options, with the ability to handle inclines and declines.

Features & Specifications

Our vacuum conveyors and belts can be configured in a variety of ways. Here is a look at standard features and specifications:
  • Available on Dorner industrial conveyor platforms.
  • End and center drive compatible.
  • Rack and pinion belt tensioning.
  • Sealed ball bearings.
  • Vacuum source is provided by a regenerative vacuum blower.
  • Standard belting is recommended.
  • V-guided and non-V-guided belt compatible.
  • Friction belting is available for rigid parts like plastic caps, plastic bottles, ceramic wafers, glassware, etc.
  • Electrically conductive belting is available for thin products such as paper, light cardboard, cloth, plastic film, etc.
You can reference specific conveyor specification sheets for additional details or contact one of our representatives for more information.

Accessories & Customizations

Our vacuum belt conveyor systems work with a variety of accessories, support stands, gearmotors and mounting packages. Examples options include:
  • Light-duty, standard-duty or heavy-duty gearmotors.
  • Side, bottom or top mounts.
  • Fixed and adjustable height stands, including a quick-adjust option.
Additionally, the vacuum area of each system is custom-designed for your desired application.

In-House Vacuum Belt Production

All vacuum belts are made at Dorner facilities to ensure optimum part-holding ability and perforation pattern quality. Our qualified team oversees all quality assurance, and this means more-reliable vacuum conveyors and systems for the customer. Our 140,000-square-foot facility uses lean production techniques, which allows us to design, build and deliver custom vacuum conveyors and other engineered solutions with reduced lead time. Many of our solutions can be delivered within five days. As with other standard belts, our vacuum belts are run through a drill punch machine, where the holes are created. Every vacuum belt is custom-created. The machine is programmed with the specific length, hole size, hole spacing, etc. This ensures everything is created to the exact specifications needed for our customer’s unique application. The drill punch machine has a wide range of sizes that it can create, so almost all vacuum belts are able to be created in-house.

Vacuum Conveyor Manufacturers

Among vacuum conveyor manufacturers, Dorner is the largest supplier of vacuum belts in the industry. Our products are engineered and tested to ensure optimal performance. We stand by our designs and offer a 10-year warranty. Dorner’s expert sales staff is highly trained in conveying products and technology as well as industry applications. Our team uses this knowledge to help our customers find solutions to their business challenges.

Vacuum Conveyor Installation Services

Dorner is not only a leading conveyor manufacturer but a top vacuum belt conveyor installation company. We’ll send our engineering experts to your location to ensure your equipment is optimized for efficient performance. Our expert vacuum conveyor installation service includes delivery, staging, setup and training.  If you plan to handle installation internally or hire an outside contractor, we can also provide a  Dorner service team member to serve as an on-site supervisor.

Vacuum Conveyor Training Services

To reduce downtime and increase safety and productivity of your workers, it’s crucial your team is adequately trained. Our knowledgeable field services team provides on-site training in maintenance, safety, troubleshooting and other relevant areas. Our vacuum conveyor training services can be done in groups or one-on-one, and it can take place during installation or down the line. After and between training sessions, your team will have 24/7 access to a wealth of online resources such as videos and guides.

Vacuum Conveyor Maintenance Program

Dorner offers a conveyor belt maintenance program in two tiers: labor plus parts and labor. With a focus on preventative maintenance, this service begins with an on-site evaluation of your vacuum conveyor system. After we assess your needs, we’ll create a custom plan that includes our recommended service intervals. This maintenance program covers a range of tasks, including inspection, adjustments, debris removal and lubrication. If you’re on the parts and labor plan, you will also receive a 10 percent discount on parts.

Vacuum Conveyors

When your products or components are small, lightweight and moving at a steady speed, you need a transfer solution that will keep things on track, literally. Vacuum conveyors use suction to hold items of all sizes in place as they move along, up and down the belt.

Vacuum Belt Conveyors

Among all of your conveying options, vacuum belt conveyors are ideal when you’re working with small, flat parts and other lightweight, thin materials. Like all Dorner conveyor solutions, our vacuum belt conveyors come in a variety of configurations, enabling you to optimize your physical space while keeping your production and budget needs in mind. Some models handle varying elevations, enabling you to fit them into tight spaces. Additionally, a range of add-ons and accessories help meet your product and process needs. See vacuum conveyor belt technology in action in this video showing small packaged goods running on the underside of a conveyor.

How Do Vacuum Conveyors Work?

Vacuum conveyors work by creating suction that keeps items flat on the belt surface. For example, a vacuum conveyor belt could prevent sheets of paper, plastic parts, cardboard, leaflets, small pouches, or empty plastic packaging from flying away as they move down the line.

This suction power is created by an internal vacuum pump that pulls air flows through perforations within the belt. This creates a seal, keeping items intact.

Each vacuum conveyor is custom designed based on the customer’s application and product. Dorner’s engineers work with our customers to figure out the proper belt and hole spacing, pattern and size.

Vacuum conveyors use a custom bed plate with a vacuum chamber to focus the suction on the proper place. Ports are custom-drilled into the conveyor frame for the vacuum. The number of ports drilled depends on our customers’ needs.

There is no vacuum on the conveyor tails. The suction prevents any slipping or sliding of the product while the product can still be easily lifted away from the belt.

Dorner can provide the blower assembly or our customers can provide their own.

Vacuum Conveyor Applications

Vacuum conveyors are seen in a variety of industries, from health care and pharmaceuticals to manufacturing and metalworking. Within these and other industries, vacuum conveyors are useful for many specific applications, including: 

  • Inspection
  • Precision part movement
  • Small part handling and positioning
  • Work holding
  • Part and package infeed and outfeed
  • Printing
  • Automated assembly
  • Manual assembly

How Do Merge Conveyors Work?

Merge conveyors work by combining multiple lines of product into a single line. Businesses come to Dorner seeking to merge two or more lanes into a single lane.

Customer Case 1

One customer needed to enhance its process of merging two lanes of frozen pizzas into one lane. This customer’s former equipment required an employee to manually intervene to ensure product flowed through smoothly. Dorner’s solution enabled this company to create a product merge that works automatically. Dorner’s merging conveyor systems provide for automatic merging and a smooth and safe transport of product, resulting in decreased downtime and increased productivity and efficiency.

Customer Case 2

Another customer called on Dorner for a merge conveyor solution to singulate randomly spaced product moving at a very fast speed. The product exited a cleaning and drying unit across four lanes and moving at 40 parts per minute. After merging, the product entered an X-ray machine at a speed of 160 parts per minute. The Dorner team merged the product using high-speed sensors, servo motors and 2200 Series Pacing Conveyors. Two common infeed conveyors initially gap the product before redistributing to four individual servo conveyors, serving as lanes.

Customer Case 3

Yet another customer sought a merge conveyor to move small plastic bottles. Dorner’s Engineered Solutions Group utilized a 2200 Series SmartFlex conveyor as the mainline units as well as a powered side guide at the transfer points. The guide uses a Dorner 2200 Series Belted Conveyor with a high friction belt. This belt helps grip each bottle, keeping it from tipping over while transferring it from one conveyor to the next conveyor along the line.

Ways to Use Merge Conveyors

Merging conveyors can be used to consolidate product flow from multiple infeed lines, and these conveyors can work in different ways. The right kind of merge solution for your business depends on your specific application along with product characteristics. The Dorner team can create a custom merge conveyor that’s engineered for your business’ needs.

In-House Vacuum Belt Production

All vacuum belts are made at Dorner facilities to ensure optimum part-holding ability and perforation pattern quality. Our qualified team oversees all quality assurance, and this means more-reliable vacuum conveyors and systems for the customer.

Our 140,000-square-foot facility uses lean production techniques, which allows us to design, build and deliver custom vacuum conveyors and other engineered solutions with reduced lead time. Many of our solutions can be delivered within five days.

As with other standard belts, our vacuum belts are run through a drill punch machine, where the holes are created. Every vacuum belt is custom-created. The machine is programmed with the specific length, hole size, hole spacing, etc. This ensures everything is created to the exact specifications needed for our customer’s unique application. The drill punch machine has a wide range of sizes that it can create, so almost all vacuum belts are able to be created in-house.

Vacuum Conveyor Manufacturers

Among vacuum conveyor manufacturers, Dorner is the largest supplier of vacuum belts in the industry. Our products are engineered and tested to ensure optimal performance. We stand by our designs and offer a 10-year warranty.

Dorner’s expert sales staff is highly trained in conveying products and technology as well as industry applications. Our team uses this knowledge to help our customers find solutions to their business challenges.

Vacuum Conveyor Installation Services

Dorner is not only a leading conveyor manufacturer but a top vacuum belt conveyor installation company. We’ll send our engineering experts to your location to ensure your equipment is optimized for efficient performance. Our expert vacuum conveyor installation service includes delivery, staging, setup and training. 

If you plan to handle installation internally or hire an outside contractor. 

Dorner service team member to serve as an on-site supervisor.

Vacuum Conveyor Maintenance Program

Dorner offers a conveyor belt maintenance program in two tiers: labor plus parts and labor. With a focus on preventative maintenance, this service begins with an on-site evaluation of your vacuum conveyor system. After we assess your needs, we’ll create a custom plan that includes our recommended service intervals.

Our vacuum conveyor training services can be done in groups or one-on-one, and it can take place during installation or down the line. After and between training sessions, your team will have 24/7 access to a wealth of online resources such as videos and guides.

Vacuum Conveyor Installation Services

Dorner is not only a leading conveyor manufacturer but a top vacuum belt conveyor installation company. We’ll send our engineering experts to your location to ensure your equipment is optimized for efficient performance. Our expert vacuum conveyor installation service includes delivery, staging, setup and training. 

If you plan to handle installation internally or hire an outside contractor. 

Dorner service team member to serve as an on-site supervisor.

How Do Conveyor Diverters and Sorting Conveyors Work?

Conveyor diverters and sorting conveyors work by handling product based on such characteristics as weight and shape along with line capacity.

  • One Dorner customer required equipment adjustments to introduce new tubs of salad greens to its production line. For applications that require modularity but that do not require a complex solution, a divert arm would suffice as a simple yet effective solution.
  • Moreover, in this case, using an AquaGard 7350 as the base conveyor offers a system that features FDA-approved belting and components. This application also includes a powered transfer that is used to maintain speed through the transfer to ensure production efficiency is at its peak.
  • Additionally, a type of conveyor diverter boasting the ability to retract or extend, retracting tail conveyors can enable a number of functions, elevating any business’ workflow.

Ways to Use Conveyor Diverters and Sorting Conveyors

Businesses know that controlling the continuous flow of product through a line is absolutely necessary to achieve peak productivity and efficiency. When conveyor diverters and sorting conveyors are used, product flow takes shape using several methods and components, all hinging on the kind of product, flow path and equipment with which to interface.

The ideal conveyor diverter or sorting conveyor solution for your business is contingent on your application and product makeup. Dorner’s team of experts can fashion a custom conveyor diverter or sorting conveyor that’s tailored precisely for your business’ special needs. Let’s examine several ways to divert and sort product.

Diverters and Gates

Product can be diverted using static guides and plows or dynamic gates and paddles.

This equipment can:

  • Change product direction to single or multiple locations.
  • Meter flow to specific areas or to separate products based on certain attributes.
  • Be controlled via proximity switches, photo eyes and counters.
  • Achieve motion via pneumatic or electric components.

Pushers

Pushers can be mounted along a conveyor’s sides or overhead depending on the product and stroke length required.

Pushers can:

  • Move product from the conveyor perpendicular to the flow.
  • Be used to remove or transfer parts to other equipment or conveyors.
  • Be used to create horizontal stacks of products.
  • Be controlled through use of proximity switches, photo eyes and counters.
  • Achieve motion with pneumatic or electric components.

Lane Guiding

When lane guiding is utilized, multiple product lanes can be created across the width of a conveyor belt.

Lane guiding can:

  • Accumulate large quantity of product.
  • Divert product across lanes.
  • Merge multiple lanes to a single lane.
  • Support unstable product.

How Do I Customize My Conveyor System?

If your business needs a specially made merging, diverting or sorting conveyor, you can turn to Dorner to develop the optimal solution! As a leader among merging, diverting and sorting conveyor manufacturers, Dorner has earned a sterling reputation for creating custom solutions that solves our customers’ throughput problems while dramatically improving their team’s ability to be efficient.

Our custom merging, diverting and sorting conveyors are designed by our talented Engineered Solutions Group. Our expert team can modify a standard solution to meet your business’ needs or collaborate with you to build a completely custom system.

Our Engineered Solutions Group will work with your team from concept to completion. Our design process encompasses needs analysis, CAD modeling, mechanical design and other services.

Additionally, Dorner’s DTools is a conveyor configurator that gives users the power to design and engineer top-to-bottom conveyor packages or just select single components.

Merge, Diverting and Sorting Conveyor Installation Services

Dorner offers complete merge, diverting and sorting conveyor installation services. With the Dorner team taking on your equipment’s setup process, your business will benefit from money and time savings compared with handling installation all on your own.

Dorner’s experienced engineers can ensure a fast and simple startup. Your business will receive delivery, staging, setup, debugging and maintenance training.

You can be sure your merge, diverting and sorting solution will be installed optimally. Your team will be able to use your conveyor equipment right away, enjoying the ultimate in performance while keeping your production line running.

Merge, Diverting and Sorting Conveyor Training Services

A key component of Dorner’s merge, diverting and sorting conveyor installation services is our conveyor systems training. Dorner’s field and service professionals can work with your team to ensure they are knowledgeable about and comfortable with using our equipment.

Your employees will gain a clear understanding about how to operate your merge, diverting or sorting conveyor. Moreover, your business will gain from our equipment’s ability to promote peak efficiency and productivity with only a gentle learning curve.

Dorner’s conveyor training services are available for a fee.

Merge, Diverting and Sorting Conveyor Maintenance Program

Dorner’s merge, diverting and sorting conveyor maintenance program can help your team keep your equipment in position to deliver unrivaled performance and dependability. Your business will receive an on-site visit at no cost to evaluate your needs along with a proposal to receive just labor service or labor service with any needed parts along with a belt inspection and adjustment.

As part of our preventative maintenance program, Dorner also provides our customers’ conveyors with an inspection plus lubrication and installation of worn belts, pulleys, bearings, drive train, gearmotors and accessories. Your team will benefit from our expert training on belt tracking and tensioning. Lastly, your business will receive an audit of your existing conveyor parts and 10 percent discount on parts ordered through our maintenance program.