We've Got Answers
We’ve compiled a list of commonly asked questions below for quick reference. Of course, if you don’t find an answer here, just contact us and we’ll be happy to chat!
Oh, and you should see the list of the less common questions we get. The quick answers are:
- While it’s possible to get Grandma’s chair upstairs with our systems, builds are already in place that are designed for such a purpose that won’t get us sued.
- That is correct; we DO have the second-largest Popeye memorabilia collection in Chester, IL.
- No, you can’t ride it.
general faq:
Material handling is a fancy way of saying “moving product.” The term encompasses any movement, protection, storage, or control of products while they are being made (manufactured), stored (warehoused), or shipped (distributed). It can sound intimidating, but don’t be fooled. It is simply moving something and making something happen to it along the way. However, it’s critical for improving efficiency, reducing downtime, and keeping operations safe and organized!
Uh, all of them?
We work with manufacturers across food, pharma, automotive, electronics, personal care, and more—anywhere individual parts weigh less than 50 lbs and you need smart, efficient handling!
Yes! From concept to installation and ongoing service, our team is with you every step of the way. We’re not just a vendor—we’re your integration partner!
It varies on your application. Our systems are customized. They aren’t commodities.
However, we will always work within your budget to maximize value. Just be upfront with your requirements. Whether you’re adding a cobot box erector, single conveyor, or automating a full line, we’ll quote transparently and fairly.
It could be two days or it could be a year. Timelines vary A LOT depending on project scope and material availability.
But most tabletop conveyor systems are built, tested, and installed in 4-6 weeks.
And our robotic solutions are usually 6 weeks +.
We make it easy!
Just give us a call at 618.826.5086 or fill out our contact form. Tell us what part you are looking for or you’re moving, and we’ll take care of the rest!
conveyor faq:
For any project you need to consider: your product (size, weight, durability), what needs to happen to it (your process/integration reqs), where it needs to go (layout), how fast it needs to get there, how you will interact with it, your future needs, and your environment.
Overwhelmed? Call us!
It depends on your product and application, but don’t default to “wider is better!”
In many cases, a narrower conveyor with good guiderail is more efficient—and more affordable! Read more on our blog about when narrow is better.
All of them!
Tabletop (modular plastic chain) conveyors, belt and roller conveyors, heavy duty conveyors, and more—we partner with multiple manufacturers to design conveyors to handle everything from food and pharma to end of line and automotive! Each system is tailored to your product, space, and process.
It depends on your product, space, and process. From incline belts to spirals, wedges, Alpines (our personal favorite), and more—there’s no one-size-fits-all. Check out our blog for a breakdown of 7 great elevation options and when to use them.
Replacing / repairing chain is usually done at the drive where catenary sag is present.
Many X65 / X85 conveyors, or conveyors with guided drives, have adaptable sections specifically for connecting the links, but you can take the side plates off of the idler and replace the chain there if needed.
Download the assembly manual to learn more.
Maybe? Inspect your wear strip (aka slide rail, or the plastic that the chain rides on) every 250 hours of runtime, and look for dust buildup on the outside of the beam or shiny spots in vertical bends where anodizing is wearing down.
Replacing it protects your chain and keeps your conveyor running longer.
It depends on your product and how often your line changes over. If you’re running multiple product sizes daily, automatic adjustment may be worth the investment. If you’re dealing with sensitive materials or odd-shaped parts, we’ll help you choose the best material and layout.
Learn more on our blog.
It depends on your product and space!
You may see them called different things, but buffers store parts between operations to keep your line moving, even if one machine stops.
We offer a wide range of buffering solutions like bi-flow tables, Alpine conveyors, serpentine systems, and vee chain buffers.
Common conveyor safety hazards include pinch points and entanglement – caused by unguarded equipment, falling products, and not following safety procedures, like lockout/tagout, during maintenance.
Addressing these hazards with proper guarding, signage, training, and system design is essential for protecting your team!
robot/cobot/automation faq:
Automation streamlines repetitive tasks, increases throughput, reduces labor costs, and minimizes errors. It helps your team focus on higher-value work while improving consistency and output!
Robot applications:
- faster
- heavier payloads
- require caged environments for safety
Cobot (collaborative robot) applications:
- slower
- lighter payloads
- built in safety features to reduce (not always eliminate!) the need for guarding
Programming both is getting easier, but cobots are often more intuitive, making them ideal for applications requiring program / application changes.
Yes! Cobots are designed for flexibility. We will work with you to retrofit existing lines with collaborative automation that scales with your operation.
A robotic palletizer automatically stacks products onto pallets using a robot arm. It’s faster, safer, and more consistent than manual stacking—especially for high-volume operations!
It varies per system, but usually our customers see ROI between 6-18 months, thanks to labor savings, reduced downtime, and increased throughput.
We’ll help you run the numbers!
palomat faq:
A PALOMAT pallet magazine is a standalone or inline device that automatically stacks or destacks empty pallets – no bending, lifting, or wrestling with pallets required!
It’s a game-changer for manufacturing, warehouse, and logistics operations that use pallets daily. With the push of a button a Greenline, or standalone, pallet magazine can load or unload one pallet at a time while holding a stack of up to 25 pallets.
PALOMAT units automate a task that’s typically dull, dirty, and dangerous; making it easier to stay OSHA-compliant, reduce injuries, and eliminate pallet damage.
Pallet dispensers come in standalone (Greenline) units that dispense pallets at floor level for pick up with a forklift or pallet jack, units that integrate with AMRs or AGVs, or inline units that dispense onto conveyors.
Yes! PALOMAT inline units are designed to dispense or destack pallets onto conveyors.
Absolutely! PALOMAT Greenline units, also called standalone units, can work with forklifts or pallet jacks, but if your facility uses AMRs or AGVs there are PALOMAT units that work with those too using WISE modules or OPC interfaces.
And if you want to load or unload your PALOMAT AGV/AMR unit with a forklift you can do that too!
It depends on the model and your pallet weights, but most standard PALOMAT units hold between 15 and 25 pallets at a time.
Greenline / Standalone models: 15–25 pallet capacity
AMR / AGV models: 15 pallet capacity
Inline models: 15 pallet capacity
Need to handle 48” x 40” GMA pallets? Half pallets? Euro? Double-ups? PALOMAT has options, and Flex-Line can help you pick the right fit for your line!
PALOMAT units are available for a wide variety of pallet types and sizes, including:
GMA wood pallets
CHEP pallets
Plastic and metal pallets
Euro pallets
Half pallets or custom sizes (explored on request)
The key is pallet uniformity! PALOMAT systems are designed to work with consistent stacks of the same type of pallet, so mix-and-match stacks or heavily damaged pallets will not work.
Want to check if your pallets are compatible? We’re happy to help!
Electric PALOMAT Greenline (standalone) units are plug-and-play and need 120V AC power.
They only consume power during pallet handling (lifting/lowering) rather than continuous operation – which makes them more energy-efficient than fully automated pallet handling systems.
PALOMAT Greenline (standalone) units operate at floor level, so they need a flat surface with sufficient ceiling height for pallet stacking and unobstructed access for forklifts or pallet jacks.
Units have a 60″ x 61.3″ footprint and are either 92.5″ tall for 15 pallet capacity units, or 147.6″ tall for 25 pallet capacity units.
A PALOMAT Greenline (standalone) unit removes the need for bending and heavy lifting when handling pallets.
Since manually stacking or unstacking pallets often causes: back injuries, pinched or crushed fingers, shoulder injuries, and tripping hazards utilizing a PALOMAT improves ergonomics and safety.
Which in turn helps facilities reduce injury claims, improve working conditions, and protect employees from preventable strain.
It can even help reduce forklift traffic – since pallet magazines can be loaded/unloaded with a pallet jack!
A PALOMAT Greenline (standalone) unit needs a flat surface to work, but units can operate in heated or cooled facilities – including inside freezers!
