MDR tote conveyor
Mainway Sortation Conveyor System

Unmatched Material Handling, Automated & Conveyor Systems

Whether you are trying to cut labour costs, increase accuracy, improve output or reduce processing time, we build systems to meet your throughput requirements – guaranteed.

Our senior staff have an average of 33 years of experience each, and our entire team follows a formal solutions creation process based on our expertise and our inclusive, flexible collaboration with you.

Gravity Conveyor

Low Investment – High Throughputs and Efficiencies

Gravity Conveyors are one of the most cost effective and versatile product lines available. These conveyors are excellent for both permanent and temporary conveyor lines often found in warehouses, shipping departments and assembly areas. Gravity curves and spur options can add to the versatility of straight conveyors

Roller Conveyor

Mainway Gravity Roller Conveyor

Skatewheel Conveyor

Mainway Gravity Skatewheel Conveyor

Ball Transfer Conveyor

Mainway Ball Transfer Conveyor
  • Economical solution for manual product transport or gravity flow
  • Versatility allows items from small to large and light to heavy to be handled
  • Supports products with irregular surfaces including loosely bagged products
  • Common applications include moving or staging products and aiding in the transport of goods
  • Economical, lightweight, non-powered conveyor suitable for conveying light products
  • Ideal for portable applications
  • Close axle centers and tight wheel patterns allows small products to be handled
  • Multiple wheel pattern choices for your product
  • Built to your length or easily field cut to length
  • Common applications include truck loading and unloading, rack-mounted product storing and staging, workstations and assembly lines
  • Economical solution where products must be manually transferred
  • Utilized when products need to be manually rotated or positioned
  • Multiple ball spacing choices, lengths and widths available
  • Secure stud-style mounting
  • Common applications include workstations, assembly lines, manual product staging and feeding

Belt & Lineshaft Conveyor

An Energy Efficient Means of Conveying for Multiple Applications

It’s simple design and versatility made it a good fit for many manufacturing and warehousing applications. This type of conveyor could be used for s-turns diverts and merges. Now implementing longer stretch of a conveyor, line shaft would need more drives but when using a belt driven live roller, it would only need one

Belt Conveyor

Mainway Belt Conveyor

Lineshaft Conveyor

Mainway Lineshaft Conveyor

Belt Conveyor brings increased efficiency to applications such as assembly lines, sorting, inspection and transportation. Belt conveyors provide a versatile means of handling a wide variety of products from bulky boxes and bundled items to furniture, wood sheets, totes and packaged goods.

  • Provides the most versatile means of handling a wide variety of products
  • Achieves higher speeds than other conveyor types
  • Many belt options for specific applications
  • Common applications include assembly, sorting, inspecting and transportation

Lineshaft Driven Live Roller Conveyor is optimal for conveying light products (15 lbs./roller) at speeds of 25 to 120 FPM. They are designed for flat-bottomed, evenly distributed loads, such as those found in distribution and warehousing, food packaging and parcel handling. One motor can power up to 100 feet of conveyor, reducing costs of power consumption, installation and maintenance.

  • Economical conveyance of loads up to 75 lbs. or 15 lbs. per roller
  • Easy add slaved components; curves, spurs and transfers
  • Increased driving force with optional keyed spools and high tension bands
  • Full line of standard modular accessories
  • Common applications include box, tote or tray transportation and minimum pressure accumulation

Powered Conveyor

Designed for truck loading and unloading along with other applications

We manufacture, install and service a complete range of custom engineered and designed conveyor products for truck loading and unloading along with other applications for manufacturing, assembly, order fulfillment, and packaging operations. Whether your operation requires a belted, skate wheel or roller conveyor, we have the conveyor equipment you need

Flexible Gravity Conveyors

Mainway Gravity Flexible Conveyor

Flexible Powered Conveyors

Mainway Flex Power Conveyor

Rigid Drive-Out Conveyors

Mainway Rigid Powered Conveyor

Rigid Modular Conveyors

Mainway Rigid Modular Conveyor

Telescopic Belt Conveyors

Mainway powered telescopic conveyor

Flexible gravity conveyors offer an economical solution for loading items into the inside of a truck, and vice versa. These conveyors can be easily expanded to reach from within a store or from the end of a fixed conveyor to the front wall of the trailer. They can also be gradually contracted or expanded as the trailer is filled or emptied for maximum efficiency and ergonomic benefit. Flexible conveyors can be curved into various configurations to deliver to multiple loading docks. Flexible conveyor solutions allow for fewer operators, increased speed, improved ergonomics and safety, and more efficient loading and unloading.

Benefits

Options for flexible conveyor that we carry include:

Width: 18”, 24” or 30”

Axle center distance: 5.25” standard, with 3” and 4” options

Skate wheels (for skate wheel conveyors): Steel, black or red

Flexible gravity conveyors are used in a variety of industries including:
  • Distribution centers
  • E-commerce warehousing and fulfillment
  • Retail
  • Third-party logistics
  • Food manufacturing and distribution
  • Manufacturing and packaging

Bridging the gap from a permanent installed conveyor to a delivery truck — whether for loading or unloading — can prove difficult. This step may introduce inefficiencies, time and resource sink, and even unanticipated safety risks into fulfillment and receiving processes. A flexible conveyor ideally addresses these issues in a versatile, space-efficient way. It also creates an ergonomically sound addition to existing conveyor systems and enables fast, efficient loading or unloading of packages.

Power flexible conveyor solutions are ideally suited to augment an existing conveyor system when:
  • Storage space is limited or at a premium
  • Loading and unloading configurations are temporary and subject to change quickly
  • Multiple loading or unloading points are required

Benefits

Power conveyors, such as flexible power roller conveyors, can take your conveyor solution to the next level of productivity and efficiency. They provide advantages in safety, footprint space, storage space and more. Flexible conveyor benefits include:

Configuration versatility: Whether you need the flexible powered conveyor to move around corners, meet multiple docks, or navigate close quarters where other infrastructure or equipment is present, a power flex conveyor can fulfill those requirements.

Increased productivity: Without a flexible powered conveyor, facilities may have to make do with existing options that are not designed to address the loading or unloading process. These types of ad hoc solutions negatively impact speed and productivity in setup and handling. Flexible conveyors solve these problems through fast integration and a direct connection from the permanent conveyor system to the dock.

Improved safety and ergonomics: By eliminating workarounds and extra steps in moving packages between the truck and the end of the permanent conveyor, these conveyors offer ergonomic benefits, reduced injury risk, increased safety and more efficient package handling.

Decreased storage footprint: Flexible conveyors can be almost fully collapsed when not in use, resulting in a much smaller storage footprint than other options. Industries that use flexible conveyors include:

Flexible powered conveyors are used in a variety of industries including:
  • Distribution centers
  • E-commerce warehousing and fulfillment
  • Retail locations
  • Third-party logistics (3PL)
  • Food manufacturing and distribution
  • Manufacturing and packaging
  • Parcel Post

Rigid drive-out conveyors make it easy to move packages from permanent conveyor systems into trailers with optimal ergonomics and little effort from the operator. A rigid drive-out roller or belted conveyor is perfect for heavy-volume, high-impact applications that run around the clock or in multiple shifts throughout the day. In fact, a rigid truck loader is built to withstand the most heavy-duty usage that may occur in loading and unloading applications.

In addition, rigid drive conveyors are ideally suited for packages of different sizes, especially when utilizing the optional herringbone transition that centers packages and provides a seamless transition from the conveyor to the loader.

Benefits

Rigid drive-out conveyors offer numerous benefits. These conveyors are designed to be driven from the conveyor installation all the way into the trailer. They are suitable for containers up to 53’ deep. This makes the rigid truck loader excellent for a broad range of loading applications across industries.

Rigid drive conveyors offer:

Ergonomics: Manually placed flexible conveyors tend to be demanding for operators throughout a day as they pull conveyors in and out of trucks to load them. By contrast, our rigid drive out conveyors can be driven into and out of the truck with the push of a button from a single operator, creating much safer ergonomic operation.

Heavy-duty applications: Robust structural steel construction provides a durable base for products of all sizes to be transported into the truck without the worry of damage from forklifts or other hazards in the shipping area. Our heavy-duty conveyors gain additional stability from durable solid rubber tires that never go flat and can easily negotiate plates and other uneven surfaces.

Belt-operated or rigid roller truck loader options: To fully meet the needs of any type of package size, shape, weight and format, we offer two truck loader options — belt-operated or rigid roller. Depending on your application, we can provide the right conveyor for you, enabling consistent, reliable movement of any size package, large or small; any shape, including irregular shapes; and any type of package, including boxes, bags and more.

Industries and applications where rigid conveyors are typically used include:
  • Distribution centers
  • E-commerce warehousing and fulfillment
  • Retail
  • Third-party logistics (3PL)
  • Food manufacturing and distribution
  • Manufacturing and packaging
  • Wine and spirits

We specialize in maximizing efficiency and adaptability through conveyors that can be quickly set up and configured for different layouts, and just as easily reconfigured, taken down and stored. We focus on modular conveyor solutions that make loading and unloading as fast and seamless as possible, integrating into modular conveyor systems that are ideal for scenarios where spikes, surges or seasonal peaks occur, as well as changes in layout to use floor space efficiently and meet shifting needs.

A modular roller conveyor offers numerous benefits in shipping and receiving functions

Fast reconfiguration: By design, conveyor modules can be quickly and easily set up, moved, and integrated in or removed from existing modular conveyor systems. The modular capabilities of a reconfigurable conveyor allow personnel to take advantage of conveyor benefits, when needed, while maximizing floor space usage at other times.

Efficient package sorting: With a modular setup, packages can easily be sorted when coming off the truck, according to the needs and arrangement of your facility. Modularity even affords the ability to create different setups for various suppliers, shippers and product types — providing the flexibility necessary to succeed in today’s evolving material handling landscape.

Reduced investment through portability: Beyond simple reconfiguration within one facility, the conveyor can be easily moved between facilities. This maximizes usage efficiency and reduces infrastructure spend by eliminating the need for full-fledged, new systems and providing just as much technology and light automation as needed.

Rigid modular conveyors can be utilized to create systems for a variety of applications including package transfers, semi-automated sorts and tying in manual packaging / work stations. These solutions can be quickly installed or reconfigured thanks to modular design, minimal components and hardware, and simple controls that utilize 120 VAC power.

Industries in which a reconfigurable conveyor solution are advantageous include:
  • Distribution centers
  • E-commerce warehousing and fulfillment
  • Retail
  • Third-party logistics (#PL)
  • Food manufacturing and distribution
  • Manufacturing and packaging

When it comes to loading and unloading trucks, an extendable conveyor can make a world of difference. These solutions extend all the way from the permanent conveyor to the nose of the truck trailer, making the process of getting cargo in and out faster, easier and safer.

Telescoping conveyors will integrate with your existing material handling infrastructure — providing a durable, versatile, effective solution to speed loading and unloading.

When your facility integrates one of our telescopic conveyors into its operations, you will enjoy numerous benefits, including:

Productivity: Reduces loading and unloading time by reducing the number of operators and effort in these processes. Telescopic conveyors accomplishes this through easy extension and retraction, intuitive operator controls, optimal ergonomics, and seamless integration with the existing permanent conveyor solution.

This means tasks that would normally involve multiple operators, extended walking time, and inefficient picking and packing, can now be completed quickly and safely with just an operator or two — depending on package sizes. This results in faster turnaround and higher fulfillment rates. 

Safety: With its ergonomic design, our telescopic boom conveyor is easier for employees to use safely. It cuts down on the risk of repetitive stress injuries as well as strains and other exertion injuries by placing the loading or unloading point at an ergonomically favorable point for the operator. This ultimately leads to lower costs and less downtime.

Less idle time: Without an extendable conveyor solution, much time is spent walking or forklifting packages and boxes from the permanent conveyor end to the dock (or vice versa), and additional time moving items to (or from) the innermost areas of the container. This additional handling time is considered idle time — since it is not actively contributing to the completion of the process. An extendable conveyor eliminates this wasted time by bringing the conveyor right to the loading or unloading point within the trailer.

These advantages make our equipment the perfect choice for a wide range of industrial and commercial environments. Virtually any industry with heavy shipping and receiving needs can reap significant rewards from implementing a telescopic belt conveyor solution, including e-commerce fulfillment, distribution centers, parcel handling and trucking terminals.

Customized for Your Needs 

With a variety of lengths, widths, options and accessories, telescopic conveyors will help achieve all of your material handling goals. We stand committed to engineering the solutions you need for your specific truck loading or unloading requirements. As part of that commitment, we also provide a wide range of accessories and options.

Motorized Drive Roller (MDR)

The Future of Smart Automated Conveyor Systems

Modern powered roller conveyor systems use motorized rollers mounted within the conveyor frames. They’re compact in size, quiet and safe with 24 volt DC power. As a result, motorized rollers have become the dominant type of conveyor system in use today. Warehouses and distribution centers rely on these conveyors for fast, smooth package movement. Importantly, sensors and controls ensure packages don’t get damaged by crushing against each other.

MDR Conveyors with cardboard boxes for 3PL

The Future of Automated Conveyor Systems

Motorized drive roller (MDR) conveyor sections are sections that utilize a single motorized conveyor roller that is only mechanically linked with enough free-turning (gravity type) rollers to constitute a controllable zone. This zone is usually not much longer than the item to be conveyed. With the proper control system strategy, you can easily assemble individual MDR zones like building blocks to make zero pressure accumulation conveyor sub systems, particularly for traditional carton type handling applications.

MDR conveyor sections with the proper control system strategy are inherently modular, both mechanically and electrically. Instead of having a single 100-ft. accumulation conveyor with its big 5HP, 480-volt gear motor, and its own air feed drop; you now have 10 manageable 10-ft. modular accumulation sections that connect together. You don’t have to supply air piping, and your power sourcing can be as simple as plugging into a standard 120-volt household wall receptacle.

Energy Savings

Typically, conventional conveyors run all the time whether they are accumulating product or not. One of the greatest aspects of motorized drive roller conveyors is the fact that, with the proper control system strategy, MDR zones only run when they need to. In a typical MDR system, the rollers in any given zone only run 10% to 50% of operational time. You could realize a savings of 30% to 70% in energy savings alone, which means a faster return on investment for your business.

Safety

Large, conventional motors can be extremely dangerous for your warehouse personnel. A stray hand, limb, or piece of clothing can lead to tragic injury if caught up in a bad place or pinch point while the conveyor is running. In addition, such motors use tremendous amounts of power, which can also present warehouse dangers. The motorized drive roller in a typical MDR zone is powered by 24 volts DC, and has no major pinch points. Moreover, MDR only has to provide motive power and torque to a short zone, so there is never enough drive power to be dangerous. In most cases, you can literally grab a running motorized roller with your bare hand and make it stop with only a handshake grip.

Motorized drive rollers can help protect your ears, as well. MDR conveyor systems are much quieter than conventional conveyors. Conventional conveyor usually uses chains and sprockets somewhere in its drive train. Vibration is then transferred to conveyor frames, supports, and rollers, and the resulting noise can be a significant hazard. To make matters worse, in most conventional systems, the motor and drive train runs all the time, so you have chain noise and vibration whether or not you are conveying or accumulating product. Motorized drive roller conveyors operate relatively quietly, and only run when necessary. MDR systems typically achieve noise levels of 70dB or less.

Plug & Play

The phrase “plug and play” has become ubiquitous in product marketing. Many companies and products promise you “plug and play” because it sounds nice, but fail to deliver the “plug” or the “play.” Motorized drive roller conveyor systems make “plug and play” a reality.

With the proper control system strategy applied up front, a typical motorized drive roller section is electrically pre-wired at the manufacturer prior to shipment. A typical section will utilize plug connectors at each end to allow the unit to be set in place and simply plugged into the unit in front of it and the unit behind it to make it operational.

As a result, you can easily add or remove sections of conveyor as needed to alter or re-route your conveyor path (even temporarily) to accommodate the changing needs of your business. Also, with the proper control system strategy applied, this endeavor need not require a gaggle of engineers, programmers, or technicians to accomplish. In some cases, your own people can make changes and modifications with minimal assistance from the original conveyor equipment or control system provider.

MDR is becoming the Standard on conveying

Most conveyor manufacturers have embraced the motorized drive roller conveyor concept in one form or another. As time goes on, motorized drive roller products are being placed on the market to solve traditional material handling functions other than just zero pressure accumulation. There are currently several versions of merges and transfers on the market, and there’s more to come.

MDR Maintenance Advantage

The inherent advantages of motorized drive roller conveyor design mean your maintenance and spare parts costs are dramatically lowered.

Because MDR conveyors only run as needed, there’s less wear and tear to the component parts. Most of the maintenance and wear associated with conventional conveyors comes from the drive train (sprockets, chains, belt lacing, etc.). Even the most modern and efficient gear motors require regular maintenance and lubrication.

The typical motorized drive roller, however, utilizes sealed for life bearings, which means much longer base equipment life. Moreover, for any given system, most of the motors will be interchangeable, which means you only have to stock one spare part. Contrast this with the typical conventional system where gear motors can differ greatly in size within a single conveyor system, each one needing its own stock of spares, and the advantage of going with MDR is clear.

Control Systems

The right design concept is the key to getting the most out of your MDR conveyor system. The conveyor equipment industry provides the mechanical building blocks and tools to move materials, but the control system is what makes it go, slow down, speed up, and stop when you need it to. The ideal control system for motorized drive roller conveyor is distributed within each conveyor section, because each section only needs to know what is going on in front of it, and only needs to tell the section behind it what it’s doing.

Control strategies that allow for data and information handling within an MDR control system further open the door to utilizing MDR solutions by enabling more intelligent functionality, such as product tracking and sorting. Until now, these things have been the sole province of conventional conveyor systems with custom control systems.

Sortation Conveyor Systems

Sorters are the ideal solution for separating products from in-feed conveyor lines to shipping lanes, palletizing operations, packing stations & other sortation needs for your operations

A unit sortation system receives bulk items in totes or master cases from picking, and sorts each item into a discrete order. This enables drastically increased (as much as 200%) pick efficiency, lower operation and labor costs, quicker order fulfillment, greater scalability for peak, and increased order accuracy. Our automated sortation systems use a variety of induction methods in combination with our sorter trays and custom chutes in the process of sorting items into correct outbound orders. Our sortation systems have an array of applications, from batching individual orders to consolidating multiple orders into a manual or automated putwall, and even sorting returned items back into put-away groupings by aisle or product type

Horizontal Cross Belt Sorter

Mainway Vertical Sorter

Vertical Cross Belt Sorter

Mainway Vertical sorter

Bombay Sorter

Mainway Bombay Sorter

Shoe Sorter

Mainway Shoe Sorter

Horizontal High-Performance Cross-Belt Sorter

The energy-efficient high-performance crossbelt sorter is suitable for applications and industries where the size and weight of the items plays a central role. It sorts material up to a maximum of 50 kg, e.g. cardboard boxes, parcels, small packages, packaged foods, catalogue goods, padded envelopes, multimedia products, clothing, etc. 

Faster, more flexible and even quieter. The new high-performance system is capable of handling up to 20,000 conveyed goods per hour. This new solution also allows much heavier and larger goods to be sorted.

Mechanical Design

The new High-Performance Crossbelt Sorter continues to rely on the proven, robust mechanical design of its predecessor. There was no reason to make major changes to a design concept that has been working seamlessly for so many years. However there have been a number of smaller upgrades to make it even more durable, i.e. narrower tracks to prevent items from falling in and obstructing the carriers’ path and to make it easier to stack. All in all, this is still the most reliable Crossbelt Sorter on the market.

Inexpensive Maintenance

Maintenance for the High-Performance Crossbelt Sorter is extremely easy and inexpensive. This is true for many reasons. First of all, the drive chain has been replaced with a rubber belt. This makes lubrication a thing of the past! Secondly, it is now much easier and faster to replace the belt. However, our extensive tests indicate this will not happen for many years even in the case of 24/7 operations. Carriers are also replaced much faster, and wear parts are also less expensive, making overall maintenance costs significantly lower than with a conventional Crossbelt Sorter!

Vertical Space Saving Cross-Belt Sorter

The main feature of vertical crossbelt sorter with linear, straight routing (“above – below”) is its distinctive space-saving design because of its compact, modular approach. For example, a width of just 1.7 m is sufficient to install a vertical sorter with 400 × 400 mm crossbelt carriers. This configuration can also save valuable space, if full containers are transported into the sorter. This is unique on the market. The infeed on the vertical sorter usually starts with an accumulating conveyor in front of the actual sorter – a simple conveyor belt. Operators are able to manually feed goods directly onto this accumulating conveyor – a cost-effective and ergonomic solution. The accumulating conveyor can, of course, also be loaded via semi-automated or fully-automated infeeds.

Bombay / Split Tray Sorter

The Bombay sorter is named after the iconic way that the bay doors on the bottom of an aircraft split open. The bottom tray panel is split into two sides that are connected by our patented linkage technology which allows for the quick and simultaneous release of both sides of the tray bottom, dropping the sorted item perfectly flat into the outbound tote or carton.

The Bombay Sorter comes in three different tray configurations: single split tray, dual split tray, and a unique quad tilt tray. All of our split tray sorter configurations provide multiple solutions for sorting round objects, odd-shaped items, and other non-conveyable products that can be challenging for other bombay sorters. Additionally, our modern take on the bombay style unit sorter is offered in 17 unique tray sizes, opening the door to endless customization, modularity, and throughput options.

Sliding Shoe Sorter

Sliding shoe sorters can be engineered with standardized or modular components for faster, easier installation and greater flexibility in divert placement. Designed for high speeds, enhanced safety and faster commissioning, shoe sorters delivers the highest throughput rates and most effective product handling.

High-Speed Performance

Motion-controlled electronic switch technology ensures accuracy at high speeds

Industry-leading throughput rates with the fastest standard speeds and patented gapping technology

Enhanced Safety and Maintenance Features

Drive and idler guards prevent access to transitions between belt and flights 

Customer-specified guards span the length of each intermediate section

Optional, integrated side and bottom panels 

Re-designed, modular, standardized components reduce on-site spare parts stocking

Ease of Installation

Integrated components feature modular, standardized construction for quicker assembly and commissioning

Simple, flexible placement of diverts anywhere along the length of the sorter for easy installation adjustments as needed

Mainway Automated Trailer

Reduce Costs, Increase Safety & Perfect Parts Sequencing

Our expert team of engineers can design and integrate a custom conveyor trailer system to suit any production needs while reducing the labour, forklifts and costs

Mainway Automated Trailer Conveyor
Mainway Multi Level Automated Trailer Conveyor

Meeting all your Production Needs

  • Reduces labour needs
  • Increased productivity
  • Greater efficiency
  • Less forklifts
  • Optimize production flow
  • Increase in workplace safety

Driving New Standards in Efficiency & Reliability 

  • Cost reduction through automation
  • Error free in sequence parts delivery to the line
  • Maximum density to optimize efficiency
  • Transparency and visibility
  • Connected operations to digital applications

Able to be Customized to Handle

  • Tires
  • Intrument Panels
  • Seats
  • Front End Modules
  • Bumpers
  • Engines

Electric Flow Tilter

Minimum Floor Space for Maximum Up-Time

Our expert team of engineers can integrate your chain driven electric Flow Tilter solution allowing for maximum up-time, ergonomic design and precise materials handling during production.

Mainway Electric Flow Tiler
Mainway Electric Flow Tiler

Meeting all your production needs

  • Increased productivity
  • Customized solutions
  • Save floor space
  • Greater efficiency
  • Low maintenance
  • Optimize production flow
  • Increased worker safety

Driving new standards in efficiency and reliability

  • Variety of in-feeds & out-feeds
  • Large load capacity – 3000 lbs
  • Customized units available
  • Adjustable height for max operator ergonomics

Transform Your Operations Today

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