Global Material Handling System Integrators

Gapping Belt Induction

Get every box scanned, labeled and delivered with gapping conveyors

Gapping belt induction conveyor (Gappers) is used when gaps need to be pulled between incoming product to assure a good read & sort prior to being put through label applicators or printers, box strappers, barcode scanners, motion scales & the sorter. By accelerating or decelerating gapping belt conveyor you maximize the throughput and minimize the gap between products entering the sorter.

Bastian Solutions has a strong history of gapping belt induction conveyor installtions across many industries. Let us help you achieve new levels of automated sortation accuracy.

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How Gapping Belt Induction Conveyor works

When exiting a merge and prior to scanning and sorting, cartons must be separated by gaps to assure good barcode reads & sortation. A gapper consists of two conveyors operating at a slightly greater speed than the incoming flow of cartons, which “pulls a gap” between adjacent cartons. Historically, these gaps have been in the range of 12 to 18 inches, but with advanced sorters coming on, the gaps are shrinking to 8 inches or less. Gapping Belt conveyor has the ability to do both dynamic and static gapping based on software and control systems.

In “Blow Through” gapping, the gapper conveyors operate at a fixed speed and the ratio between the conveyors is fixed. The “pitch”, or distance between the leading edges of the products, tends to be a fixed distance. If the application has a wide variance between small and large boxes, wide gaps can occur. This is possible wasted space and a reduction in sorter throughput.

In “gap optimization” gapping, the distance between incoming boxes is sensed and conveyor speed is quickly accelerated or decelerated, resulting in a consistent gap size. This allows you to get the maximum throughput and performance from your sorter.

ZiPline Dynamic Gapper Conveyor

The Dynamic Gapper is a feat of engineering and controls logic designed to provide consistent results for a randomized mix of products. Designed for the mail to small parcel industry, the Dynamic Gapper is comprised of two lanes, each with 4 distinct zones, that accept tightly spaced product of varying size and discharge them at a specified distance relative to one another. This complex and constantly changing speed control is performed all while accelerating the product to speeds upwards of 200 cases per minute. Having consistent gaps drawn greatly increases throughput when utilized prior to merges.


  • Length: 134 inches
  • Lane Overall Width: 20” BR minimum
  • Minimum Gap Between Lanes: 2”
  • Motor: AC induction motor (1 per zone; 4 per lane)
  • Logic: Allen Bradley
  • Rate: 200 cases per minute
  • Sensor: Banner Light Screens – capable of sensing as small as one envelope
  • Sensor: Banner Light Screens – capable of sensing as small as one envelope
  • Belt: WVT “Stretchy” belt
  • Drive: Timing belt (HTD)
  • Minimum Top of Conveying Surface: 26”
  • Roller Centers: 4”
  • Product Weight: 8 lbs. per box max
  • Final Gap: 5” ± 1” 

More Information


Gapper conveyor sorter rates are 180 cartons per minute. Maximum load capacity is 75 lbs.

Budgetary Pricing

Typical investment is $12,000- $15,000 USD.



Gapping belt conveyors create an appropriately sized gap between products to ensure that down-stream processes such as the read rate during bar-code or photo eye scanning and sortation occur efficiently and with minimal errors.


Products Sorted

Gapping Belt Induction Conveyors can sort all products that employ sortation equipment.


Gapping Belt Induction Conveyors are commonly used in all industries that employ sortation equipment.


Interested in finding your own solution?