Lowering Conveyor Noise with Ultimation

Reduce Workplace Noise with Smarter Conveyor Systems by Ultimation

 

Reduce noise, boost safety, and extend equipment life with MCE & Ultimation.

Noise is often treated as a background issue in manufacturing. Yet the hum, rattle, and clatter of conveyor systems can cost more than comfort. Research suggests that approximately one-third of our workforce is at risk for hearing loss after working in these environments.

Beyond hearing damage, prolonged exposure to high-decibel environments leads to increased absenteeism and reduced morale. Failing to monitor noise or implement such programs ranks among OSHA’s most commonly cited violations. The consequences extend beyond employee well-being. It also makes communication harder and increases operational costs.

Ultimation, an MCE company, delivers low-noise conveyor solutions to mitigate these risks and build a more productive and sustainable workplace.

The Hidden Cost of Conveyor Noise in Industrial Environments

One squeaky, squealing conveyor is annoying. Imagine the noise of thousands of rollers running in tandem.

Unchecked conveyor noise is at least, disruptive. At worst, it can cause long-term damage to your workforce and bottom line. OSHA sets the legal limits on noise exposure at 90 dBA over an 8-hour shift and NIOSH recommends a lower threshold of 85 dBA, noting that exposure beyond this level is hazardous. Many conveyor systems operating with unlubricated bearings or hard-contact rollers regularly exceed the limits set by regulatory bodies.

In loud environments, workers miss critical auditory cues such as forklift horns or alarm signals. Conversations become strained, leading to errors and miscommunication. Some companies even experience spikes in accident rates tied directly to noise-related distractions.

Younger workers, especially, are prioritizing safe, comfortable work conditions, and persistent noise can throw a wrench in your hiring goals. When facilities overlook noise risks, they increase the likelihood of hearing-related claims and make it more difficult to retain experienced workers.

Ultimation’s Low-Noise Electric Conveyor Solutions

Ultimation’s modular conveyor technologies offer a proven path to lower workplace noise. Among their solutions are 24 volt DC power-driven roller conveyors, MCP belt curves, and gravity-fed systems, each featuring a polyurethane roller cover, play a role in reducing decibel levels and improving work conditions.

Motorized Driven Roller Conveyors (MDR)

These low-voltage electric motor conveyors are designed to be quiet, operating at a noise level of under 64 dBA. They’re ideal for unit-load handling, including totes and boxes, and provide an energy-efficient way to move products without excess mechanical noise. The modular format enables custom layouts tailored to the environment.

 

Low Voltage Conveyor Noise

MCP Belt Curves

Designed to handle mixed materials, these curved conveyors deliver smooth directional changes while maintaining a low noise profile. Modularity and flexibility are the key factors in the MCP series of modules. Each pre-assembled module delivers solid technical performance as well as reliability. Their positive-drive construction reduces mechanical friction, and the system runs at less than 64 dBA, one of the quietest belt curves available.

Gravity Conveyors with Polyurethane Roller Covers

Ultimation’s gravity conveyors use the force of gravity to move the load down the rollers and are ideal for warehouses, production facilities, or distribution centers. They designed and made from materials that minimize noise, such as precision bearings and smooth surfaces, to ensure quiet and efficient operation. They also feature optional polyurethane roller covers that significantly reduce impact and vibration noise.

 

Polyurethane Cover Reduce Conveyor Noise

 

Roller Cover Options

Ultimation stocks multiple roller cover materials, including urethane, vinyl, and hard plastic. These covers also protect products from scratches and increase the grip between the item and roller for more consistent movement. In many cases, switching to polyurethane roller covers lowers overall conveyor noise by 20 to 30 decibels.

Ultimation has roller covers available in bulk or cut-to-length formats, with installation options to fit most roller conveyor systems. Many Ultimation eCommerce offerings enable customers to order conveyors with pre-installed roller covers, allowing for a faster setup.

Ongoing Support

Ultimation enhances system performance with expedited shipping of spare parts and customized maintenance plans that target wear-prone components. Whether a facility needs to replace a damaged roller or adjust conveyor flow, Ultimation provides the parts and expertise to keep systems operating quietly and without interruption.

Even the best conveyor systems rely on consistent mechanical care to stay quiet. Bearings wear down, and parts loosen over time. Noise builds up without attention to these small details. The Ultimation team tackles those issues proactively with a full line of aftermarket support.

MCE’s Portfolio of Services: Lubrication and Mechanical Upgrades from MCE-Piedmont

Quiet equipment only stays quiet when it’s properly maintained. That’s why Ultimation customers have access to service and support from across the broader MCE portfolio.

Piedmont Electric Motor, an MCE company, specializes in electric motor repair and preventative maintenance programs for conveyor systems, preserving the performance gains Ultimation’s equipment delivers.

Conveyor systems become louder when bearings degrade, or parts are left unmaintained. MCE’s Piedmont team identifies where the noise originates and applies the appropriate mechanical solution. Addressing motor issues before they escalate ensures production schedules stay on track. That might involve lubrication. In other cases, it may require parts replacement or a structural adjustment based on how the equipment operates daily.

From food manufacturing to heavy industrial environments, Piedmont applies the same maintenance principles outlined in its approach to optimizing food industry conveyor systems, ultimately reducing plant noise, reducing downtime, and extending the life of these mechanical systems.

Ultimation Conveying: Safety, Ergonomics, and Space Optimization

Lowering conveyor noise offers broader benefits beyond decibel reduction. Workers in quieter facilities are more aware of their surroundings, making it easier to hear approaching equipment or verbal cues.

Ultimation’s conveyor systems are also designed with space and ergonomics in mind. Overhead installations free up valuable floor area and reduce congestion. Flexible, collapsible conveyors can be deployed as needed and then stowed away to preserve clear work zones.

Conveyors with proper height and flow control reduce strain during loading and unloading. These ergonomic improvements translate into fewer injuries and a smoother, more consistent work pace.

>> Maximize Your Warehouse Space: Build Up, Not Out

Beyond Noise—the ROI of a Safer, Smarter Workspace

Every improvement in workplace noise control contributes to measurable returns:

  • Employees stay more focused and miss fewer alerts
  • Facilities avoid fines and workers’ comp claims tied to hearing damage
  • Job seekers are more likely to choose safer, quieter environments
  • Equipment lasts longer and requires fewer emergency repairs
  • Products stay protected during transit, reducing rework and damage claims

Quiet conveyors support a more sustainable operation both financially and functionally. Companies that prioritize low-noise systems build reputations as safe, forward-thinking employers.

Quiet, Reliable, Ready to Ship

Ultimation’s conveyor solutions are available online through their eCommerce platform, with many configurations shipping quickly. Customers can request a quote online. They can also order spare parts or connect with technical support through the site. That makes it easier to start building a quieter workspace.

A Comprehensive Partnership for Long-Term Conveying Performance

Ultimation delivers the quiet, efficient conveyor systems that set the foundation for a safer and more productive workplace. Piedmont keeps those systems running at their best with specialized service, lubrication, and mechanical upgrades that tackle noise at the source. Together, they represent just part of what MCE Automation offers.

If you’re ready to improve performance and create a better working environment, take a closer look at MCE Automation’s full network of companies. Each division brings focused expertise to support long-term reliability and stronger operational outcomes across your facility.

Contact us to find out how we can provide the foundation for a quieter, safer, and more productive workplace.

Maximize Your Warehouse Space: Build Up, Not Out with Ultimation

Pressed for additional warehouse space?

Stop thinking about square footage—and start imagining cubic footage. Warehouses across industries are running out of room. Labor is harder to find. Safety expectations are higher than ever. Building a new facility might seem like the only answer. But the cost and disruption can derail your operations and delay your ROI for years.

Ultimation’s modular overhead and vertical conveyor systems offer a better way. With these systems, you can optimize your existing footprint and automate material handling—all designed to fit your operation and ship fast.

The Real Cost of Expanding Your Facility

Construction is expensive. Today’s warehouse buildouts run $150 to $200 per square foot or more. That’s just the start – add in permits, inspections, and compliance delays that can add weeks or months to your timeline.

HVAC and electrical upgrades often require custom work, driving costs even higher. If you’re expanding into a new location, real estate and lease premiums can take a bite out of your budget. Expect lost productivity as teams navigate workarounds and construction disruptions throughout this process.

Most facility expansion projects take six to 18 months to complete. That’s time you could spend moving more product—not waiting for concrete to dry.

Vertical Solutions: Overhead Conveyors Explained 

Ultimation’s space-saving solutions make your current facility work smarter:

  • Overhead conveyors free up floor space by moving products above active work zones. These systems are ideal for transporting items through work areas without interrupting foot traffic or floor-level operations. Ultimation offers power and free (P&F) and enclosed track systems to suit a range of load capacities and automation needs.
  • Conveyors allow infeed and outfeed lines to stack vertically, increasing throughput in tight areas. Businesses can streamline material flow without expanding outward by placing multiple conveyors at different heights. Lifters can be integrated into the design to elevate or lower materials seamlessly. This space-saving approach is especially useful in applications like packaging lines, where product staging and sorting must occur in a limited footprint.
  • Systems can mount to ceilings, mezzanines, or walls for ultimate flexibility. Ultimation’s modular designs support a variety of mounting configurations, making it easy to retrofit systems into existing facilities or build new layouts from scratch. Ultimation teams can configure components like brackets, tracks, and supports to fit your unique space and load requirements.
  • Autonomous Mobile Robots (AMRs) can move freely through various work environments without needing a fixed path or operator control, helping to enhance the overall safety performance of your warehouse operations. The best planned and best run industrial facilities will likely utilize warehouse robots, floor conveyors and overhead conveyors.

These systems serve many industries: automotive plants, fulfillment centers, vertical food farms, electronics packaging, and more. Wherever space is tight, overhead systems can open it back up.

Total Cost Savings: More Than Just Floor Space

Saving square footage is just the start. Ultimation’s overhead and vertical conveyor systems deliver cost benefits far beyond space optimization. These systems do more than move materials. They reduce labor demands, improve safety, and prevent product damage, helping to eliminate hidden costs that eat into your profits.

Let’s look at how smart Ultimations vertical conveying solutions pay off across your entire operation.

Product Protection 

Rubber- and urethane-coated rollers reduce product damage by limiting vibration and slippage. They add grip and prevent metal-on-metal contact, protecting fragile items like painted components, electronics, and food packaging. Fewer damages mean fewer returns and higher customer satisfaction.

Labor Shortage Solutions 

Conveyor automation reduces the need for manual material handling, especially for jobs that are hard to fill. Fewer repetitive tasks engage your workforce in ways that lead to lower turnover. These tools can also cut labor costs by reducing overtime and the time you spend onboarding new workers.

Safety and Ergonomics 

Ultimation’s 24V DC-powered systems reduce noise, creating a safer and more comfortable workplace. Workers can hear alarms, equipment, and their coworkers, reducing the risk of accidents. Ergonomic designs reduce physical strain and injuries in your valuable labor force. These deliberately quiet systems also support OSHA compliance by reducing noise exposure in high-decibel environments.

Cost Comparison: Facility Expansion vs. Vertical Expansion

Ultimation’s overhead and vertical systems offer more than a one-time space solution; they create long-term ROI that compounds over time. Expanding your facility involves a higher cost up front and higher operational costs over time. Investing in vertical conveyors helps facilities operate leaner and smarter by minimizing space and downtime, while lowering labor demands. As your business grows, these systems grow with you, keeping your capital investments focused on efficiency rather than expansion.

Investment Option Estimated Cost Time to

Implement

 Results
Facility Expansion $150-200/sq ft 6-18 months New space, but at a high cost and long lead time
Overhead/Vertical conveyors $25-75 linear ft 2-8 weeks Quick space optimization at a much lower cost with safer and faster operations.

 

As a bonus, companies that deploy these systems create operational efficiencies, including:

  • Product damage and scrap reduction: Up to 30% fewer defects
  • Labor cost savings: 20–40% reduction in manual handling hours
  • Lower injury-related costs: Fewer OSHA fines and lost-time incidents

Facilities benefit from better visibility and safer traffic lanes when they can clear floor-level clutter and elevate product flow. With Ultimation systems in place, forklifts and workers can move freely, which can reduce the risk of accidents in highly congested areas.

These systems are also modular by design. That means when workflows change, you can adapt quickly. Need to reroute a line or add capacity? Ultimation’s modular components make it easy to scale without rebuilding from scratch.

Maintenance is another area where Ultimation adds value. Their systems are designed to work with off-the-shelf parts available directly through their eCommerce platform. This functionality makes routine upkeep and part replacements faster and more affordable. Ultimately, vertical systems keep your operation running smoothly with less downtime.

>> Ultimation Industries Forecasts Five Material Handling Trends for 2025

Synergies with Other MCE Automation Divisions

When you work with Ultimation, you get access to a larger network of automation expertise through Motion & Control Enterprises (MCE). We’ve deliberately created a one-stop shop based on our customers’ unique needs. For example, we offer integrated services in tandem with our MCE partners, such as:

  • Full-system design and project integration
    MCE- Applied Industrial Controls (ACI), an automation, controls, and drives distributor, serves industrial, OEM, and municipal customers throughout the Southeast. Their expertise in engineered systems ensures that Ultimation’s conveyor solutions can be effectively integrated into comprehensive automation projects, providing cohesive and efficient operations,
  • Robotics for pick-and-place
    MCE-RSA Solutions specializes in robotics, sensing, vision and code reading solutions that complement Ultimation’s vertical conveyor systems. Their robotic technologies facilitate precise pick-and-place operations across multiple conveyor levels, enhancing throughput and reducing manual handling. Watch this Automatic Case Packer in action.​
  • Smart conveyor control systems
    MCE-Industrial Control (IC) provides advanced control systems that bring intelligence to conveyor operations, such as their high-performance flexible feeding systems. MCE’s networking and PLC solutions can help improve the safety and efficiency of your automation processes, enabling real-time monitoring and adjustments, ensuring optimal performance and adaptability in dynamic manufacturing environments.​
  • Custom automation enhancements for complex, multi-layered solutions
    MCE-Air Automation Engineering (AAE), is a distributor of automation products and automated tooling solutions. AAE offers robotic, PLC, and DC tool programming, especially for small-parts-assembly applications with Epson robotic solutions. They also provide calibration, and repair. Their capabilities support the customization and enhancement of Ultimation’s conveyor systems, ensuring tailored solutions for complex automation needs.

By leveraging the strengths of these MCE companies, Ultimation delivers integrated automation solutions that maximize your efficiency and ROI.

Space-Saving Solutions: How Ultimation’s Vertical Conveyors Revolutionize Warehousing

Stop paying for space you don’t have—and don’t need to build. Optimize what you already own with Ultimation’s overhead and vertical conveyor systems.

Our conveying and AMR systems ship fast, our support team answers in real time, and our product pages give you transparent pricing and lead times upfront.

Building Smarter Warehouses, One Level at a Time.

Let us help you build a vertical conveying system for your facility. Schedule a free warehouse optimization consult.

Problem Solvers: Making Roller Replacements Last Longer

Problem Solvers: “The rollers on our gravity conveyor are showing premature signs of wear. How can I make sure the replacements last longer?”

While the material handling systems used in warehouses, distribution centers and manufacturing environments are designed for heavy-duty applications, higher volumes and faster speeds can prematurely wear down moving parts such conveyor rollers.

“It’s important to replace rollers as soon as signs of wear appear,” said Alec Fitzgerald, Sales and Marketing Supervisor for Ultimation. “Replacement can be a cost-effective step that keeps the entire system working reliably for years to come.”

22" Between Frame Polyurethane Roller

Alec offers the following tips for choosing an appropriate replacement for gravity conveyor rollers:

  • Gravity conveyor rollers come in a variety of sizes and weight capacities. Make sure you’re using the right roller for the job.
  • Consider the spacing of the rollers in your system. If you need higher weight capacity, space the rollers closer together to improve the total load bearing capacity.
  • Some loads may benefit from a cushion between the material and the roller itself. Polyurethane rollers and covers could be the answer. They’re temperature rated for operations within -80°F to 200°F (-62°C to 93°C) .
  • Additional loose rollers can be added to existing conveyors to provide a smoother rolling surface if smaller packages are used. For stability, products moving across the conveyor should come in contact with at least 3 rollers at any given time.

For more ideas, visit the Online Store or contact the Ultimation Customer Service team directly at (586) 771-1881.  Ultimation answers all calls during business hours with a live operator and respond to all requests within 24 hours (or the following business day for inquiries received on the weekends).

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.