Ultimation Industries’ Aftermarket Parts Give New Life to Legacy Conveyor Systems

Five signs that it might be time to replace material handling system components

ROSEVILLE, Mich. (Mar. 12, 2025) – With ecommerce expected to grow at a nearly 9% rate through 2028, warehouses and distribution centers need to be prepared for the wear-and-tear on material handling equipment as they try to keep up with demand, according to Ultimation Industries. The company also says manufacturers need to be mindful of equipment deterioration in their quest for increased productivity. Ultimation is an MCE company that solves productivity challenges with special purpose machinery and industrial automation equipment systems as well as direct-to-consumer solutions for a broad range of end-markets, including energy, automotive, logistics and vertical farming.

“While the material handling systems used in warehouses, distribution centers and manufacturing environments are designed for heavy-duty applications, the need for faster speeds and increased productivity will eventually wear down moving parts such as trolleys, chains, rollers, belts and other components,” said Kali Wahrman, general manager, E-Commerce for Ultimation. “Replacing them as signs of wear appear can be a cost-effective step that keeps the entire system working reliably for years to come.”

Material Handling Trends in 2025

Wahrman identified several signs that conveyor system components may need replacing:

  • Frequent jams. Chains in overhead conveyor systems are susceptible to elongation due to continuous usage with heavy loads and high speeds. When this happens, the chains’ ability to maintain the proper level of tension is compromised and jams can occur. Replacement chains are available in a variety of sizes, depending upon the application. Ultimation also offers chains with LubriPin™ technology, which increases the longevity of the conveyor chain by improving the flow of oil as compared to traditional conveyor pins.
  • Bearing seizures. Trolley bearings can get a workout as they move materials through production areas that humans can’t, such as through ovens and robot work cells. Heavy sustained usage can lead to internal corrosion from moisture and other contaminants, and result in bearing seizure. Replace balky beam trolleys on overhead conveyor systems to keep production moving while ensuring integrity for heavy loads.
  • Premature roller wear. Rollers on gravity and motorized conveyor systems that show signs of surface wear from heavy loads or belt contact need to be replaced before they negatively impact productivity, efficiency and safety. In some cases, a polyurethane coating may be the answer as it provides a cushion between the material and the roller itself. Seized or stuck rollers will eventually impact the rest of the system and should also be replaced.
  • Misaligned belts. Uneven belt wear, frayed edges and slippage are among the signs of misaligned or worn belt conveyors. These problems might also signal that the belt material is not appropriate for the application. General purpose belting material made of rubber or fabric can handle totes, packaged goods and bulk boxes, while rough top belts provide extra grip on inclines, declines and for products that might slide. Some belt products are cut- or chemical-resistant, while others can handle higher temperatures. Finding the right replacement belt could help improve system alignment and performance.
  • Inefficient systems. Legacy material handling systems designed for the days before the e-commerce boom may no longer provide the efficiency needed to keep up with modern Gravity conveyors, for example, can easily be converted to a motorized roller system for faster, smoother package movement. Likewise, expanding existing systems with new functionality, such as lifters or autonomous mobile robots (AMR), can result in productivity gains.

8389 X-458 Conveyor Chain

 

“Ultimation can help companies troubleshoot their current material handling systems and resolve any issues,” said Wahrman. “We have thousands of replacement parts in stock for fast shipping to get production lines back on track quickly.”

 

For more ideas on how to improve material handling, visit the Ultimation website at https://www.ultimationinc.com/ for more information.

How We Helped: Stories from Our Customers

You can’t beat Ultimation customers for ingenuity when it comes to putting our products to the test. They’ve hauled concrete, striped lawns, moved woodworking materials, launched kayaks and more with their quick-ship purchases from our on-line store.

Here’s the latest roundup of genius ideas from our customers:

Keep the wheels turning

Ultimation’s two-pack of polyurethane coated rollers were just the right thing for a customer who needed to assemble three-piece wheels without any scratches. He built a base and mounted the brackets for smooth operation. “Quality item; seems to roll good,” he writes. Other customers who bought the same product had this to say:

“Bought these to roll go-kart front end up to get tires off the ground for winter storage. These worked great for that. Their construction seems pretty good with the roller coating adhered tightly and soft enough to be non-marring but still durable. All at a very good price.”

 

“Worked perfectly for my application. I used these to make a detailing platform for car wheels. Used some recycled wood and bought a stool. Under $50 vs $165. These rollers worked flawlessly.”

 

“5.0 out of 5 stars. Better than expected! I used the roller to protect a cable that travels vertically at high speeds. I attached then to the edge of steel beams that are 4” away from the cable to protect them from damage due to sway. They worked perfectly.”

Roller and bracket set polyurethane

The rollers feature a 1.5″ spring-retained, galvanized core coated with a .062″ thick orange polyurethane roller cover that maintains its integrity within a temperature range of -80’F to 200’F (-62’C to 93’C).

I-beam, you beam, everybody beams

I-beam trolleys are workhorses in the wood shop, mechanic’s garage, auto assembly plant and just about anywhere secure heavy lifting and movement is needed. Our I-beam trolleys ensure smooth movement, even around turns with a radius of 24″ or greater. The 2-3/8″ diameter wheels and four-wheel design allow it to traverse both straight and curved tracks effortlessly.

Beam trolley garage set up i-beam

One customer who installed our industrial grade I-Beam Trolley with side guide rollers and is just waiting for an electric hoist to get started on his projects, and shared a photo of the set-up. Others praised our trolleys for their “smooth operation” and “heavy duty quality and solid design.”

These are just a few examples of the many products available as part of Ultimation’s Quick-Ship product line! Visit our online store for more information.

Ultimation Industries Recommends Material Handling Solutions for a Safer New Year

Suggestions include five products that offer better ergonomics, product safety or injury prevention

 

ROSEVILLE, Mich. (Jan. 13, 2025) – Manufacturers, distributors and warehouses can ring in a safer new year with material handling solutions that offer product protection, minimize injuries and improve ergonomics, according to Ultimation Industries. Ultimation is an MCE company that solves productivity challenges with special purpose machinery and industrial automation equipment systems as well as direct-to-consumer solutions for a broad range of end-markets, including energy, automotive, logistics and vertical farming.

 

“The new year is a great time to take stock of potential material handling safety concerns and explore options for making improvements,” said Carl Milodrowski, operations manager for Ultimation. “A well-designed conveyor system can help companies keep personnel, packages and products safe throughout the year and well into the future.”

 

Milodrowski provides five product suggestions companies can use to keep workers and products safe in their facilities:

  • Injury prevention. Safety light curtains are often used within manufacturing and industrial settings to protect personnel from injury and hazards from dangerous equipment or devices. When the light curtain is interrupted, photoelectric sensors send a signal to stop the connected machine before an injury can occur. They can also be used to safeguard machines and robots from damage. Installation of light screens is quick and easy, thanks to their compact design and the variety of mounting brackets for multiple applications.

SG4-30-030-OO-E Light Curtain Screen Set

  • Ergonomics. Eliminating repetitive bending and stretching in the workplace could be as simple as making sure the facility’s gravity conveyors are at the appropriate height. Ultimation offers stationary floor support legs in a wide range of widths and heights, with each style offering adjustable height ranges. They are available in light, medium and heavy duty versions depending upon the load weight.

Gravity Roller Conveyor Polyurethane 24in W x 6ft L with Legs

    • Another way to improve ergonomics in a warehouse or distribution center is through the use of Autonomous Mobile Robots (AMR) to carry loads that would be too heavy for humans. When fitted with an appropriate top module, AMRs can move their loads safely alongside production workers without the need for pre-programmed paths or routes. When obstacles appear in front of them, they quickly find alternate safe paths to the destination just like a self-driving car. The speed of the AMR will change according to its safety conditions. Speeds are generally in the range of 3 – 6 mph (5-10 km/h) which matches typical warehouse walking speeds.
  • Product safety. Recent news reports have been filled with stories about food recalls. While the sources of contamination vary, food manufacturers and distributors can make sure their material handling systems aren’t one of them. Food-grade conveyors are one of the most important parts of the food and beverage industry because they transport raw ingredients, organic materials and other consumable goods within the facility and ultimately out to the consumer. Unlike regular industrial conveyors, food and washdown material handling solutions must be constructed of sanitary and hygienic materials to meet rigorous safety standards. Belt conveyors are often used in food applications because they offer a smooth, continuous surface and are easy to clean.
    • Keeping products safe during their movement through a manufacturing or distribution facility can depend on the type of conveyor system in use. Motor-driven roller conveyors (MDR) are a mainstay due to their fast, smooth package movement and sensors that ensure packages don’t get damaged by crushing against each other. Various lengths, widths, zones and roller spacing configurations, including curved sections, provide the ability to customize a solution without specialized engineering expertise. Gravity conveyors can easily be converted to a motorized roller system for faster, smoother package movement.

For more ideas on how to improve material handling safety, visit the Ultimation website at https://www.ultimationinc.com/ for more information.

Ultimation Industries Forecasts Five Material Handling Trends for 2025

Artificial intelligence and other smart technologies are expected to help boost operational efficiency

 ROSEVILLE, Mich. (Dec. 13th, 2024) – Smart technologies such as robotics, automation and artificial intelligence (AI) in material handling operations are expected to be among the top trends in 2025 for manufacturers, distributors and warehouses in their quest to improve operational efficiency, according to Ultimation Industries. Ultimation is an MCE company that solves productivity challenges with special purpose machinery and industrial automation equipment systems as well as direct-to-consumer solutions for a broad range of end-markets, including energy, automotive, logistics and vertical farming.

 

“Companies of all sizes in the manufacturing, warehouse and distribution sectors are realizing that they need new technologies and sustainable options to remain competitive in an increasingly demanding marketplace,” said Kali Wahrman, General Manager, E-Commerce for Ultimation.

 

Based on interactions with its customers, Ultimation forecasts these five material handling trends for the upcoming year:

 

  1. Enhancing human labor capacity with automation and robotics. In the new year, companies will continue to automate some material handling tasks to address the ongoing skilled labor shortage in the manufacturing, distribution and warehouse sectors. Automated processes offer improved efficiency and accuracy of material movement and fulfillment processes. For example, robots are being used to move material through a facility, retrieve products or take items on or off a conveyor belt. It’s also becoming more common for robots and employees to work side by side, with the robots handling tasks that are repetitive, involve heavy lifting or are otherwise unsafe for humans.

 

  1. Harnessing data for operational efficiencies. Companies are becoming more aware that the data produced by machines and equipment can help them resolve their biggest material handling challenges. Internet of Things (IoT) technology brings together the data and information locked inside sensors, radio frequency identification (RFID) chips and other sources and gives supply chain managers new insights into their operations. For example, real-time collection of product and material data such as condition, load capacity, temperature and other metrics can be used for better decision-making to improves process flows, minimizes idle times and reduces cost. “Smart” systems such as barcoding technologies that integrate with existing Enterprise Resource Planning (ERP) and inventory systems are also being used to streamline processes and gain efficiencies.

 

  1. Working smarter with machine learning and artificial intelligence (AI). Artificial Intelligence was all over the news in 2024, with a dizzying array of possibilities for supply chains. In 2025, companies with robust digitalization strategies are looking to AI and machine learning to further improve their productivity. Both AI and machine learning automate a variety of manual processes involving data and decision making. For example, they can monitor equipment data to determine the optimal time to perform maintenance or study a facility’s energy use patterns to maximize efficiency. In the new year, expect material handling leaders to prioritize technologies that increase fulfillment accuracy, streamline inventory management, monitor equipment performance and optimize warehouse space.

 

  1. Moving toward electrification and sustainability. Electrification isn’t just happening in the auto industry. It’s also a growing trend in material handling as companies look to convert older conveyor technology into more sustainable electronic options. For example, legacy conveyor systems that run constantly are being replaced with alternatives that only use electricity when they are actively moving cargo. Lightweighting is another trend rooted in sustainability, which involves swapping out heavier materials for lighter alternatives that enhance system efficiency. Additive manufacturing, also known as 3D printing, can also play a role in sustainable operations. It can reduce waste and reduce energy usage when compared to traditional manufacturing.

 

  1. Maximizing facility footprints. In 2025, companies are expected to continue their efforts to optimize their facility footprints to improve the process flow, operational efficiency and flexibility. Conveyor systems with modular designs make planning simple if changes or expansions are required. Mix-and-match solutions across several different conveyor types, such as roller conveyors, belted conveyors and key sorting elements can easily be combined for a customized solution. Lifters and overhead conveyor systems are an affordable, effective solution that can be deployed to take advantage of otherwise unused vertical space.

 

Ultimation Industries offers a number of products and services that can help industrial companies improve the productivity and efficiency of their material handling operations. Visit the Ultimation website at https://www.ultimationinc.com/ for more information.

Ultimation Industries Introduces New Controls Package to Optimize Heavy-Duty Chain-Driven Live Roller Conveyors

Integration can be done without specialized engineering or customization when using Ultimation HD CDLR conveyors

ROSEVILLE, Mich. (Oct. 22, 2024) – Ultimation Industries’ new controls package for Chain-Driven Live Roller (CDLR) conveyors helps manufacturers, distribution centers and others move heavy materials such as pallets, racks or industrial containers without the need for customization. Controls packages manage the speed, direction and buffering of items on a conveyor to optimize productivity.

 

“In the past, integrating controls into heavy-duty conveyor systems required specialized engineering expertise,” said Kali Wahrman, general manager for Ultimation. “We’ve developed our new controls package to work seamlessly with our CDLRs without the need for customization. It is also available online for quick delivery.”

Chain Driven Live Roller Conveyor Controls Package with VFD

Ultimation is an MCE company that solves productivity challenges with special purpose machinery and industrial automation equipment systems as well as direct-to-consumer solutions for a broad range of end-markets, including energy, automotive, logistics and vertical farming.

Ultimation’s new CDLR controls package offers both 120V and 480V AC input power options. It includes a gear motor controlled by a Lenze Variable Frequency Drive (VFD) for speed adjustment and frequency inversion. The E-STOP is hardwired to the safe torque off (STO) component on the VFD for immediate emergency shutdown.

CDLR Control Package with VFD

Here’s how the new CDLR controls package works:

  • Dual photoeyes detect parts entering the system, and check for any parts positioned at the end of the conveyor.
  • If there are no parts detected at the end of the conveyor when a part enters the system, it will advance the part to the end of the conveyor.
  • If there are additional conveyor segments connected downstream, the controls check for parts in the following position.
  • The parts will follow the same process for any remaining conveyor segments, until reaching the final conveyor zone.
  • The system will wait for the push button or additional photoeye signal to advance parts from the final conveyor zone.

 

The controls package can be added as an option to an Ultimation CDLR conveyor system or purchased separately.

For more information about Ultimation Industries’ automation equipment systems as well as direct-to-consumer quick-ship conveyor solutions, visit https://www.ultimationinc.com.