Live roller conveyors use motor-driven rollers to move products efficiently across a conveyor line. Unlike gravity conveyors, each roller in a live system is actively driven—typically by a chain, belt, or lineshaft. As a result, this setup allows for precise control, smooth movement, and consistent performance across a wide range of applications.

These systems play a key role in manufacturing, warehousing, and distribution environments where unit loads like pallets, totes, or cartons need to move reliably. Because of this, each roller is powered, live roller conveyors are well-suited for handling both light and heavy items. Furthermore, they support accumulation zones, transfers, and automated system integration.

To meet varying layout, load, and control requirements, Webb-Stiles provides multiple types of live roller systems. Whether you’re looking for rugged chain-driven units for heavy-duty service or smoother-running, belt-driven or extended-range designs, each solution is custom-engineered to match your facility’s flow and performance goals.

History of the Live Roller Conveyor

Live roller conveyors emerged as an evolution of basic gravity rollers, addressing the need for powered movement of goods in manufacturing and distribution. Early roller systems relied on manual pushing or gravity-fed slopes, limiting their efficiency and control. As factories sought greater automation in the early 20th century, powered rollers became an essential solution for moving packages, pallets, and components through production lines.

The initial versions of live roller conveyors used simple chain or belt drives to link rollers together, providing positive traction and continuous movement. Over time, variations like Chain Driven Live Roller (CDLR), Belt Driven Live Roller (BDLR), and Lineshaft Live Roller (LSLR) were developed to accommodate different load types, environments, and budget considerations.

Live roller conveyors became a staple in material handling due to their versatility. They allow for accumulation, controlled flow, and integration with diverters and sortation systems, making them ideal for warehouses, assembly lines, and packaging facilities. Today, advancements in drive systems, materials, and automation continue to expand the capabilities of live roller conveyors.

Applications & Uses

These conveyor types are designed to meet a range of material handling needs across different industries and product types:

Key Features

Designed for durability and flexibility, live roller conveyors offer the following key features:

Specialized Options

• PLC-based zone control (replaces legacy ALPHA® and Bar-Logic systems)

• Grease-packed or sealed bearings based on environment

• Slip tube or pop-up zone accumulation options available

• Fixed or adjustable take-up options

• Available in both standard designs and fully custom builds

How Live Roller Systems are Engineered

Layout & Flow Design

Every live roller conveyor system begins with careful layout planning. To begin with, Webb-Stiles engineers design each system around your building footprint and the specific movement of your product. Whether you’re modifying an existing facility or building from scratch, layouts can include straight sections, curves, merges, elevation changes, and directional flow to align with your floorplan.

In addition, layout decisions factor in accumulation zones, discharge points, and upstream or downstream equipment integration. Turntables, chain transfers, and pallet dispensers can be added to redirect loads or create buffer zones. Engineers design each layout to support your current flow and accommodate future expansions.

Drive Method Selection

Drive system selection plays a critical role in performance, durability, and flow control. Webb-Stiles offers several drive types for live roller conveyors, including chain-driven (CDLR), belt-driven (BDLR), timing belt (TBLR), and lineshaft systems (LSLR).

Each option offers unique advantages. For example, Chain-driven systems are best for heavy-duty applications and high-force movement. In contrast, Belt-driven systems are smoother and quieter, often used where reduced noise is a priority. Timing belt drives deliver higher speeds and quieter operation with minimal maintenance. Meanwhile, lineshaft systems are ideal for light-duty work, especially when curves or zoning are required.

All drive types are available in modular configurations to support zone control, accumulation logic, or integration with other equipment.

Roller Type & Sizing

Roller selection is key to load capacity and consistent motion. Therefore, Webb-Stiles offers multiple roller diameters (1.9″, 2″, 2.5″, and 3.5″) in order to match your product’s size, weight, and spacing needs.

Use smaller rollers for light items or when your layout calls for tighter spacing. In contrast, larger rollers offer added strength, especially in CDLR systems, making them better suited for heavy-duty use. You can choose roller centers and shaft types based on your layout and expected wear, helping ensure durability and optimal weight distribution.

Whether you’re moving small cartons or heavy pallets, each configuration is purpose-built for long-lasting performance.

Accumulation Strategy

Every Webb-Stiles live roller system can be configured for accumulation. This feature helps control product flow, reduce pressure between items, and stage materials for downstream operations.

• CDLR and TBLR systems use slip tubes for contact accumulation. Products rest against the item ahead of them without spacing, creating a simple and reliable buffer.

• BDLR and ERLR systems use integrated pop-up zones for non-contact accumulation. This setup allows spacing between loads, reducing product damage and improving control.

• LSLR systems include built-in accumulation zones by default, supporting both contact and non-contact accumulation without additional components.

Webb-Stiles now uses modern PLC-based logic to deliver faster, smarter accumulation control. As a result, Webb-Stiles no longer relies on outdated systems like ALPHA® or Bar-Logic.

Support Structure & Framing

Support structure plays a critical role in every live roller conveyor system. Because of this, Webb-Stiles offers a full range of supports, bracing, and elevation options tailored to your floor layout and load requirements. These systems can be floor-mounted, overhead, or span multiple elevations within a single run.

Choose framing options based on load and environment. Adjustable take-ups are used where chain tension and belt alignment need long-term management. Support legs can be fixed-height, height-adjustable, or mounted on bolted leveling pads—depending on the application.

Engineers size each structural element for your system’s load and designed with accessibility in mind—for both everyday maintenance and long-term reliability.

System Integration & Customization

Live roller conveyors are typically just one piece of a larger material handling system. Webb-Stiles engineers each conveyor to integrate seamlessly with upstream and downstream equipment—whether that includes palletizers, stretch wrappers, robotic cells, or other conveyor types like belt or chain systems.

To support this integration, custom controls, sensors, and PLC programming are used to manage zone logic, synchronize product flow, and interface with plant-wide systems. Additionally, engineers can add accessories like transfer devices, diverters, and pop-up stops to control product routing and manage flow paths.

Whether your setup involves a few powered zones or full-facility integration, ultimately every live roller conveyor is engineered to meet your performance goals and system requirements.

Reference dimensions and chain specs for CDLR, BDLR, and more.

Need help selecting the right conveyor system?
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