What are Conveyor System Controls?

Every conveyor system, no matter how simple or complex, relies on controls to function. These controls manage when a conveyor starts and stops, how fast it moves, how it responds to safety triggers, and how it coordinates with other equipment. Without them, the system is just steel and motors—controls bring it to life.

At Webb-Stiles, we engineer system controls in-house to ensure total reliability. From design to programming, our electrical team handles every detail. This approach ensures that each control system is purpose-built for the application—not a generic, one-size-fits-all solution.

In many cases, system controls replace older mechanical methods of managing conveyor operations. Instead of relying on manual stops, physical switches, or separate accumulation devices, these functions now manage through intelligent controls. This shift simplifies the mechanical design and makes systems more flexible and easier to adapt as processes evolve.

For simple applications, controls manage basic start/stop functions. For more advanced systems, they synchronize multiple conveyor lines, automate load handling, and integrate with upstream or downstream equipment. Controls also play a vital role in safety, managing emergency stops and interlocks to protect people and products.

Webb-Stiles builds control systems to scale. Whether it’s a small production line or a large, multi-zone installation, controls are designed to fit the project’s demands. Environmental conditions, load capacities, and process requirements are all factored into the design to ensure reliable performance.

Because Webb-Stiles develops every control system in-house, future upgrades or changes can be handled quickly and efficiently. This long-term support gives customers confidence that their systems will continue to meet their needs as operations grow or change.

Key Elements of a Conveyor System Controls

A reliable control system consists of several essential elements, each working together to manage your conveyor’s performance. These serve as the foundation of every Webb-Stiles control solution.

Operator Stations

These controls put essential functions at your fingertips. You can start and stop conveyors, trigger emergency stops, or select operating modes with simple, reliable interfaces designed for your specific system.

Electrical Control Panels

Panels form the heart of the system’s electrical infrastructure. Built in-house, they house relays, variable frequency drives, and PLCs—organizing power distribution and ensuring smooth, reliable operation.

Custom Programming

Every conveyor system requires different solutions. Webb-Stiles designs tailored software routines that manage movement, timing, and automation, ensuring that your system performs as it should.

Field Integration & Support

When it’s time to bring the system online, Webb-Stiles electrical engineers are there. From start-up and debugging to hands-on training, they ensure everything runs smoothly and your team feels confident operating the system.

Applications & Uses

These systems are essential for managing and automating conveyor operations across a variety of settings. Common applications include:

System Automation & Device Integration

• Synchronize conveyors with automated load and unload equipment.

• Control switches, diverters, and specialized handling devices.

• Manage sequencing for multi-line or multi-zone operations.

• Integrate with plant-level control systems and PLC networks.

Scalability & Future Expansion

• Design control systems that adapt to changing production needs.

• Simplify upgrades and modifications with in-house programming support.

• Provide long-term serviceability through fully engineered control solutions.

Key Features

Webb-Stiles control systems are designed to deliver reliable performance while providing the flexibility to adapt to each project’s specific needs. From system accuracy to seamless integration, every feature is engineered to support long-term operation and simplify future maintenance.

Integration & Support

• Full in-house design, programming, and testing for seamless system integration.

• Controls synchronize with load/unload devices, diverters, and plant-level systems.

• On-site start-up assistance, system debugging, and hands-on customer training.

• Rapid response for modifications, expansions, or process changes.

• Continuous support from Webb-Stiles’ electrical engineering team throughout the system lifecycle.

How System Controls are Engineered

Designing an effective control system requires understanding more than just equipment specs. At Webb-Stiles, we approach this as a collaborative process, focusing on creating a solution that works for your operation—not a one-size-fits-all package. Every system is engineered with careful attention to how it will perform, integrate, and evolve over time.

Aligning System Design with Operational Demands

Webb-Stiles evaluates how the conveyor system fits into the overall production flow. Factors like layout complexity, product movement, and sequencing needs directly influence control design. Webb-Stiles carefully considers the number of conveyors, work zones, and integration points to ensure smooth coordination throughout the system. By tailoring the controls to these specific demands, Webb-Stiles delivers solutions that enhance—not constrain—how you operate.

Prioritizing Safety and Compliance

Webb-Stiles integrates safety requirements into every control system from the start. We account for emergency stops, safety interlocks, guarding, and real-time system monitoring. These features are essential components designed to protect personnel, equipment, and product flow while meeting facility compliance standards.

Integrating Automation and Specialized Equipment

Webb-Stiles designs controls to seamlessly integrate with load/unload mechanisms, switches, diverters, and plant-level systems. We address accumulation zones, transfer points, and synchronized device coordination through custom programming, ensuring the entire operation functions as a cohesive unit.

Building for Long-Term Reliability and Growth

Webb-Stiles engineers every control system with future needs in mind. We allow for system expansion, process adjustments, and evolving production requirements through scalable designs. In-house programming and testing streamline updates and modifications, providing long-term support without relying on outside vendors. This approach ensures the system remains reliable and serviceable throughout its lifecycle.

Ready to Optimize Your Conveyor System?

Webb-Stiles engineers complete control solutions designed to match your operation—not a one-size-fits-all package. 
Contact us today to discuss how a custom control system can support your material handling needs.