What It Is
Powered roller in zones, each with a photo-eye. Cartons queue without touching (zero pressure) and release one at a time or all together.
How the Zones Work
- 24V MDR zones: Motor roller and card per zone, no air.
- Line-shaft with clutches: Older, cheaper, less control.
- Stops and releases: One carton (singulation) or the whole queue (slug).
Sizes and Settings
| Item | Typical |
|---|---|
| Zone length | 24" or 30" (one carton plus a gap); longer zones for long cartons |
| Rollers | 1.9" on 3" centers, 24 V motorized roller every zone |
| Speed | 60 to 150 feet per minute |
| Capacity | 50 to 100 lb per zone |
| Modes | Singulation (one at a time), slug (all at once), train (gap control) |
| Sensors | Retro-reflective photo-eye per zone, one at the release point |
Where It Goes
- Before a scanner, scale or labeler.
- Before a sorter.
- At pack stations.
- Between stations at different speeds.
Controls
MDR zones run on their own; a small PLC or sorter controller times the release. We wire and tune it on day one.
Common questions
What does zero-pressure accumulation mean?
Cartons queue without line pressure, so fewer crushed cartons. How well it works depends on the sensors, controls and setup.
How long should an accumulation zone be?
The longest carton plus a few inches: 24 or 30 inches for most mixes.
Do I need a PLC for accumulation conveyor?
Not for a straight line. Add one for merges, diverts, scanners or a sorter.
What is the difference between singulation and slug release?
Singulation releases one carton at a time, for scanners and labelers. Slug releases the whole queue, for a sorter or pack station.
