Get maximum system throughput with sawtooth merges

Combiners & merges are used to merge the flow of multiple infeed lines of conveyor, typically from upstream pick modules, into a single stream of product on a single conveyor. There are several kinds of combiners and merges, and one of the most popular is the sawtooth merge.

Sawtooth merges can be used to merge conveyors that intersect at an angle. Since belt conveyors cannot have angled ends, a small triangular section of roller conveyor is needed to bridge the gap between the straight end of the infeed conveyor and the angle it meets up with the outfeed conveyor. Together, a row of these metal triangle-shaped sections look like the teeth of a saw blade, which is how they get their name.

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How Sawtooth Merge Conveyors work

Merges and combiners are used to control the flow of items from multiple upstream processes to a single downstream process like sortation, check-weighing, or scanning. Merges are typically fed by an accumulation conveyor which collects products and times their release for an organized, controlled merge. This controlled release helps downstream processes like sortation keep pace with upstream processes like order picking, maximizing the efficiency of the entire system.

Normally, products will be slug released, meaning that a full lane of accumulated product is released at once through the merge. A sawtooth merge application can accumulate product in a round robin fashion, meaning that it accumulates product on one or more lines while releasing on a different line, providing maximum throughput of product downstream. Sawtooth merges are the best option for high-speed merges with a large number of infeed lines.


Benefits & Applications

  • Good option for merging a large number of infeed lines
  • Capable of handling a variety of containers including totes, boxes, parcels, cartons, boxes, etc.
  • Helps control flow of products between processes
  • Maximizes system efficiency for downstream processes like sortation, checkweighing, or scanning


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

  • Desired throughput rate
  • Number and type of infeed conveyor lines
  • Type, size and weight of items being transported
  • Product handling needs
  • Facility layout

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