Plastic Belt Conveyor & Accessories
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Bastian is proud to offer the next big thing in modular plastic belt technology with the introduction of Intralox® Activated Roller
Belt™ Technology (ARB). This unique, patented technology is a system comprised of rollers embedded within a durable modular plastic belt. The rollers can be orientated on 0, 30, 45, or 60 degree angles, or in any combination of these angles depending on what the application calls for. There are two types of rollers available. A smooth roller works for most applications but a high friction rubberized roller is available for applications
that call for a high degree of positive drive. These rollers protrude above and below the belt's surface and when activated provide
lateral movement to products of all weights and sizes. The only size limitation is that products with a side smaller than 4 incheswill not convey properly due to the roller spacing. And in general, the product should have a flat, rigid bottom to maximize the
conveying surface area to insure proper belt function.
Below is a list of ARB applications that Bastian currently offers. Bastian, along with Intralox, offers the use of extremely powerful physics engine software to simulate and test product interaction on each application before final approval as well as offering free product testing for every application.
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Sortation and Diverting Conveyor
The Activated Roller Belt technology creates a very effective sortation conveyor that can be single or dual-sided. The positive drive of 36 rollers per square foot of belting enables, ARB sorters to handle a wide range of product sizes, all the way down to 4" x 4" with single-sided and 8" x 8"
with dual-sided sorters. This includes hard-to-sort items such as DVD's, books, electronics, fasteners, as well as heavy items.
Take-away conveyors can be at 20, 30, or 45
degree angles depending on the specific applications. And, unlike most alternative sorter technologies, divert locations can be tightly spaced to reduce the overall footprint of
the sorter. With accurate sort rates up to 100 cpm, a wide range of product sizes
and weights, the ARB sorters offer a sound choice with compelling value.
| Benefits: | Budgetary Pricing: |
| Smaller footprint | $9,000 USD per divert |
| Wide range of products | |
| Lower maintenance and operational costs versus other sorter technologies | |
| Sortation rates up to 100 cpm |
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Left or Right Alignment Conveyors
The Activated Roller Belting alignment conveyor is one of the most positive ways to ensure your products are consistently aligned to the left or right. As product is randomly introduced, the ARB system gently drives the product to one side of the conveyor in a uniform fashion, usually up against a guard rail. ARB with rollers set at 30 degrees is typically used, but 45 degree roller angles can be used in combination to align packages in a shorter space. An example of both applications can be seen to side.
| Benefits: | Applications: |
Budgetary Pricing: |
| 1/2 the distance required relative to skewed rollers | Scanner Sections | $9,000 USD |
| Reliable, accurate product justification | Print and Apply Label Areas | |
| Pre-Sortation | ||
| Recirculation Loops |
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Descrambler-Singulation-Depalletizing Conveyors
The definition of singulation is to take a group of side by side products and form them into a straight line with proper
justification. This is achieved typically with three conveyors, each driven with VFD motors. The first conveyor
starts the descrambling process. This conveyor generally needs to be wider than the conveyor feeding the product due to the resulting
product rotation. The second conveyor finishes the descrambling action and centers the product as well as starting the justification
process. The third conveyor achieves the proper justification by aligning the product to a guard rail. By doing so, the product
is properly prepared for downstream events such as merging, print and apply, or sortation. This application is also perfect for depalletizing
product where an entire layer is deposited and broken up to prepare for further processing.
| Benefits: | Budgetary Pricing: |
| Reduces Sortation Errors and Jams | $30,000 USD |
| Reduces Recirculation Rates | |
| Improves Scanner Read Rates | |
| Small Foot Print (12-36ft depending on flow rate) | |
| Low Maintenance Solution |
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Merge Conveyors
There are two categories of merge technologies available: 90 degree and in-line. A 90 degree merge is where
product is introduced to a second conveyor that is flowing perpendicular to the previous conveyor. An in-line merge, sometimes called a combiner, is where two
lines feed into one line down the center or to one side of the conveyor. Each can accommodate a number of situations and offers a
number of benefits.
| Benefits: | Applications: | Budgetary Pricing: |
| Reduced jams and maintenance | 2:1 Merge | $15,000 USD |
| Small foot print | 3:1 Merge | |
| Eliminates damage caused by guard rails and plows | 90° Merge |
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Perpetual Merge™ Conveyors
The Perpetual Merge™ is changing the game when it comes to prepping packages for sortation applications. Perpetual Merge Conveyors merge two or more lines together without the need for long accumulation lines or stop and go motion. This unique, patented concept allows packages to move continuously at lower conveyor speeds while still meeting throughput
requirements. These advantages are achieved by using Activated Roller Belting with 0 degree rollers and equally spaced cleats. The slower speeds and continuous
motion reduces wear and tear on the belts, drives, and motors, reducing maintenance costs significantly. Implementation costs are
also lower due to the lack of complex controls and automation needed for this technology to function. Also, the elimination of accumulation conveyors, not only saves cost, but allows for a very small foot-print to achieve the same desirable end result. The product spacing conveyor component of the Perpetual Merge can also be used standalone, as a simple
gapping device.
| Benefits: | Budgetary Pricing: |
| Elimination of accumulation and controls | Starting at $15,000 USD |
| Increased throughput | |
| Continuous motion and precise gapping | |
| Low maintenance and long life | |
| Small foot-print |
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Switching Conveyors
Activate Roller Belt Technology offers a superior alternative to expensive slat and pusher arm switches. As packages are introduced to the switching conveyor, they are sorted and discharged onto multiple, parallel conveyor lines. 1:2 and 1:3 switching variations are available depending on what the situation calls for. ARB switches are quieter, safer, and require significantly less maintenance than horizontal slat switches.
| Benefits: | Applications: | Budgetary Pricing: |
| Rates up to 80 cpm | Beverage Industry | $23,000 USD |
| Precise product justification | 1:2 Switch | |
| Increase line efficiency | 1:3 Switch | |
| No safety cage needed | ||
| Low Maintenance Solution |
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Case Turn Conveyor
This Activated Roller Belt application uses 30 degree rollers to proper justify packages against the guard rail before the case turner. This
ensures that packages hit the case turner at a consistent point which reduces the number of misaligned products before additional sortation
operations as well reducing line jams. One difference between this technology and traditional methods is the ability to stop the conveyor
belt without losing proper product orientation. As the belt restarts, the rollers ensure that the product follows the same path and continues
to hit the case turner at the proper moment. Package momentum is not necessary to complete a full rotation. Another perk is that the case
turner can be retro-fitted to existing 30 degree Activated Roller Belt alignment conveyors.
| Benefits: | Budgetary Pricing: |
| Start and Stop ability | $14,000 USD |
| Handles wide range of product sizes | |
| Simplifies the case turn operation | |
| Easily retro-fitted to existing installations |
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Palletizing Conveyor (Passive Layer Former)
Activated Roller Belt technology can be used to simply and automatically create pallet layers that can be presented to
a palletizing robot. The concept uses a combination of an actuated case turner, and a specially configured Activated Roller Belt conveyor that precisely arranges packages to create a pallet layer. With the use of controls and integrated IO, this system can properly start
the pattern and then adjust to make sure that the layer is properly balanced with the introduction of the next row of products. Flow rates up to 60 cases per minute are achievable depending on package size and layer pattern. ARB palletizing conveyors offer a simple, low maintenance solution with a small footprint and the ability to handle a wide variety
of product sizes and weights.
| Benefits: | Budgetary Pricing: |
| Lower cost versus manual palletizing | $23,000 USD |
| Low maintenance | |
| Small footprint | |
| Flexible for future system requirements |
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Activated Roller Belt™ Technology, as defined, is really a system comprised of belting, rollers, and of a carryway. A carryway is a device located beneath the belt that provides positive drive to the rollers embedded within the belt. These carryways can be created by using a high friction smooth top surface, or a set of idler rollers within the conveyor frame positioned parallel to the direction of conveyor flow. Applications that call for 0 or 30 degree rollers will typically use a high friction smooth top surface. Angled rollers of 45 or 60 degrees employ the idler roller carryway. When positive drive to the rollers is not required, the belt itself rides along smooth UHMW strips that are equally spaced within the conveyor rails.
