Steel and polymer gravity roller lane tracks for medium to heavy carton, tote, and bin flow — precision ball-bearing rollers in multiple diameters and pitches for reliable, low-maintenance FIFO lane feed in manufacturing, assembly, and warehouse operations.
Roller track is available in 1.375-inch (35mm), 1.9-inch (48mm), and 2.5-inch (63mm) roller diameters. Larger diameter rollers are specified for heavier loads and lower rolling resistance per unit load. Roller pitch (center-to-center spacing) is selected so that every container base contacts at least two rollers at all positions in the lane.
Galvanized steel tube rollers provide maximum load capacity and durability for heavy totes and metal bins. Full-polymer polyethylene rollers are used in food-grade, washdown, and cleanroom environments where corrosion resistance and sanitation access are required. Steel-core polymer rollers combine load capacity with corrosion-resistant surfaces.
All rollers run on double-sealed, permanently lubricated ball bearings pressed into the roller tube end caps. Ball-bearing rollers have significantly lower rolling resistance than plain-bore or spring-tension axle rollers, enabling gravity feed at shallower inclines and extending roller service life in high-cycle applications.
Track sections are supplied in 12-inch (300mm), 24-inch (600mm), and 48-inch (1200mm) lengths for assembly into any lane depth. Track sections butt-join end to end on the frame support rails and are secured with a bolt-and-T-nut at each support point, allowing any lane depth to be assembled from standard section lengths.
Spring-brake rollers and pneumatic brake roller inserts are available for high-incline lanes or heavy containers where uncontrolled acceleration to the pick face would cause product damage or present a safety hazard. Brake rollers are drop-in replacements for standard rollers at selected positions in the lane.
ESD-dissipative polymer roller track is available for lanes handling electrostatically sensitive components. ESD roller surfaces have a surface resistivity of 10^6 to 10^9 ohms per square and integrate with the grounded frame system to provide a continuous ESD discharge path through the lane to facility ground.
35mm, 48mm, 63mm standard; custom on request
Galvanized steel tube or full polyethylene
Double-sealed ball bearing; permanently lubricated
300mm, 600mm, 1200mm standard
3.5 in to 24 in standard; custom widths available
Up to 150kg per roller (diameter and pitch dependent)
Spring-brake or pneumatic brake roller inserts
ESD-dissipative polymer roller; 10^6–10^9 Ω/sq
T-nut and M8 bolt; universal T-slot mounting
Medium and heavy carton gravity flow lanes in warehouse pick modules and manufacturing supermarkets where roller track provides reliable, low-maintenance FIFO flow for corrugated cartons and rigid bins.
Industrial tote and metal bin flow lanes adjacent to production lines and assembly stations where heavier load roller track sustains multi-shift high-cycle operation without bearing replacement.
Component tote supply lanes at assembly workstations where precise lane pitch ensures consistent container presentation height at the pick face for ergonomic operator access.
Multi-tier gravity pick modules in warehouse order fulfillment operations where roller track provides high lane density and low operating cost compared to powered conveyor alternatives.
Roller pitch (center-to-center spacing between rollers) should be selected so that the smallest container used in the lane contacts at least two rollers at all positions along the lane depth. A common rule is to set roller pitch at no more than 40% of the container base length. For example, a container with a 300mm base length would use a maximum 120mm roller pitch. If multiple container sizes share the lane, pitch is based on the smallest container.
Load capacity per roller depends on roller diameter, roller material, and bearing selection. Standard 48mm galvanized steel ball-bearing rollers are rated to approximately 80kg per roller. 63mm heavy-duty rollers are rated to 150kg per roller. Lane capacity is calculated from the number of rollers simultaneously supporting the container and the total number of containers in the lane. Modular Solutions can provide a lane load calculation for any specific container and lane configuration.
Yes. Roller track sections can be cut to any length using a standard metal-cutting saw. The cut end of the track is deburred and the end roller position is adjusted to maintain correct pitch. For custom lane depths that do not divide evenly into standard 300mm, 600mm, or 1200mm section lengths, Modular Solutions can supply cut-to-length sections or the customer can cut standard sections on site.
Brake rollers are installed at a specific position in the lane — typically two to four rollers back from the front stop — to slow container descent before the container contacts the pick-face stop. The braking position and the number of brake rollers depend on the lane incline, container weight, and the allowable impact force at the front stop. Modular Solutions can perform a braking calculation to specify the correct brake roller position and count for any given lane configuration.
Yes. Roller track lane geometry is compatible with robotic pick systems that require a consistent container presentation height and position at the lane front. For automated applications, lane front stops are designed with a defined container stop position and optional RFID or barcode scan point at the pick face. Modular Solutions works with the automation supplier to confirm rack interface requirements before finalizing the lane design.
Share your container dimensions, lane count, load per lane, and incline angle — we will specify the right roller diameter, pitch, and brake arrangement for your application.
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