Merges and Combiners

Seamlessly Merge Product Streams for Efficient Downstream Processing

Merge and combiner automated technology is used to arrange products flowing from multiple infeed lines of conveyor. Commonly, merges are introduced to combine product from upstream pick modules with multiple lines into a single stream of product. The merging process then sends a single stream of products downstream for further processing often into a sorter, in-line scale, or scanner.

Applicable across industries, merges and combiners offer a variety of options to meet your specific throughput and business objectives. Bastian Solutions experts work with you to identify the best solution for your operations.

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How Merges and Combiners Work

Merges, in general, consolidate conveyor lines into one single lane. Products from multiple lanes are released into a single lane. Combiners, on the other hand, is when conveyor lines are fed into a single wide merge area that serves as a funnel prior to traveling to the narrower, merge takeaway conveyor.

Sawtooth Merge Conveyors - A sawtooth merge is used to combine a potentially limitless number of infeed conveyor lines into one conveyor line. Commonly this process occurs before the induction of a product into a sorter. Learn more about sawtooth merge conveyors >

Live Roller Merge Conveyor - A live roller merge is used to combine two to four conveyor lines into one conveyor line. A wide live roller conveyor is used in conjunction with a fixed or powered plow to combine the infeed lines.

Belt Merge Conveyor - A belt merge is used to combine two to four conveyor lines into one conveyor line, in high speed applications. Belt merges do require the use of a powered plow to combine the infeed lines.

Spur Merge Conveyor - A spur merge is used to combine together two conveyor lines. It is a very cost-effective merge in operations which do not demand high throughputs.


Features & Benefits

Merges and combiners offer a fairly simple, yet valuable function. They help to bridge the gap between upstream and downstream processes, which reduces the need to manually transport and sort products. Additionally, other benefits of this sortation conveyor technology include:

  • Simple configuration and flexibility for reconfiguration
  • Improve warehouse flow
  • Minimize labor load handling



Bastian Solutions’ experts will work with you to explore potential turnkey or custom options. Consider the following details when exploring shoe sortation solutions:

  • Type, size and weight of items being transported
  • Upstream and downstream activities and automated equipment
  • Merge speed
  • Desired throughput
  • Number of merged lanes, infeed lines
  • Facility layout and space constraints



See More Sortation & Conveyor Solutions


Sortation Systems


Conveyor Systems

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