What is an Overhead Conveyor?

An overhead conveyor is a material handling system that moves products along a suspended track, allowing items to travel above ground-level operations. These systems use trolleys mounted to an I-beam or enclosed track to transport parts through workstations, paint booths, ovens, or storage areas—without interrupting activity below. Overhead conveyors are especially useful in facilities where floor space is limited or where equipment needs to move across complex production zones. Compared to floor-mounted systems, they free up valuable real estate and reduce the risk of ground-level congestion or collision.

Overhead systems can be configured for continuous or stop-and-go movement and may include features such as elevation changes, curves, or switches. Many facilities integrate these systems into assembly lines, finishing systems, and high-density storage layouts to support efficient product movement through multiple manufacturing stages.

History of the Overhead Conveyor

The overhead conveyor has its roots in late 19th-century innovations that transformed material handling and manufacturing. Early developments came from pioneers like Andrew Betts Brown, who in 1863 invented the overhead travelling crane used in building London’s Blackfriars Bridge. This concept evolved further in 1876, when Sampson Moore designed the first electric overhead crane for hoisting heavy loads at the Royal Arsenal in Woolwich. By 1892, John Ridley Temperley introduced the Temperley transporter, an early version of the overhead crane that moved materials more efficiently and laid the groundwork for the systems we recognize today.

While these early inventions focused on lifting and moving heavy items, they set the stage for continuous movement systems that would soon become essential in manufacturing. The overhead conveyor, as a production tool, gained widespread attention in the early 20th century when Henry Ford integrated it into his automotive assembly lines. Although Ford did not invent the overhead conveyor, his pioneering use of it to streamline vehicle production revolutionized manufacturing and made the technology a staple in factories worldwide.

Since then, overhead conveyors have continued to evolve, becoming vital for industries that require efficient, space-saving material handling solutions. Their ability to improve workflow, maximize floor space, and adapt to a variety of applications ensures their relevance in modern manufacturing environments.

Types of Overhead Conveyors

Applications & Uses

These systems are versatile and commonly used in the following production and movement settings:

Finishing, Storage & Movement

• Finishing systems: painting, curing, drying, or coating lines

• Part accumulation zones with stop/start capability

• Overhead routing across facility zones or levels

• Buffering between manufacturing and storage areas

• Cross-floor or cross-department part delivery

Key Features

Engineered for performance and flexibility, overhead conveyors offer:

Functionality & Integration

• In-house manufactured trolleys for Power & Free systems

• Compatible with Monorail and Power & Free configurations

• Stop/start functionality and accumulation zones

• Integrates with PLCs, sensors, and robotics

• Configurable for cleanrooms, high-heat, or corrosive environments

How Overhead Conveyor Systems are Engineered

It Starts with the Space

The layout defines the system. We map out your load and unload zones, workstations, clearances, and building structure. Overhead conveyors are ideal for weaving through tight spaces, around equipment, or above floor-level traffic — but only when planned with precision. Every path, elevation change, and support point gets factored in from the beginning.

The Load Shapes the Hardware

What you’re moving — its weight, size, and handling method — determines the trolley size, track size, and chain. Smaller loads may use X-348 chain and 3″ track. Heavier items may call for X-678 with 6″ track and sealed full-complement trolley wheels. As a result, even the attachments vary — from clevis pins and hooks to custom brackets and load bars.

Turns, Curves, and Transitions

Not all curves are the same. You’ll find both traction wheel and roller turns available in pre-engineered 30°, 45°, 60°, 90°, and 180° options. Engineers select each one based on space, speed, and load. For Example, vertical dips, inclines, and transitions get their own attention, too — because what goes up must be safely guided down.

Take-Ups, Drives, and Chain Pull

Whether manual, spring-loaded, or air-operated, take-up units keep the chain tensioned. Then the drive: Caterpillar or sprocket, chosen based on pull requirements and layout conditions. Behind the scenes, our engineers calculate chain pull, moving load, and lift forces to make sure every component — from drive size to curve radius — fits the system’s workload.

Hanging Methods and Safety Guards

How the conveyor hangs depends on your ceiling height, bay spacing, and structural steel. We design the supports to match your building, not force your building to fit our supports. And depending on your application, engineers add custom conveyor guards to protect workers and equipment alike.

For Power & Free Systems

We determine where loads should accumulate and how they’ll stop, switch, or sequence. Each switch is engineered based on flow, layout constraints, and carrier spacing to maintain throughput and minimize interruptions.

Ready to talk through your system?
Contact our team to start a conversation about your application, space, or load requirements.