Conveyor System Upgrade Solution – Energy Optimization for Modern Logistics Centers

In the logistics and e-commerce industries, energy efficiency in operations has become a top priority. A large-scale distribution center in Europe successfully upgraded its existing conveyor system using advanced technology, achieving significant reductions in power consumption while improving the working environment.

Challenges

• Constantly changing logistics demands driven by new fashion trends, peak seasons, new product lines, and new customers
• A highly complex infrastructure with over 7 km of conveyors and more than 12 million SKUs
• An urgent need for an energy-saving strategy with ambitious reduction targets

Sustainable Upgrade Solution

Instead of replacing the entire system, the operator retained the existing conveyor structure and upgraded key components such as drive motors and control units. A critical element of this improvement was the application of the Interroll RollerDrive EC5000—an intelligent drive solution featuring zero-pressure accumulation.

This approach optimized system performance without major structural modifications, enabling a fast, cost-effective upgrade with no disruption to ongoing logistics operations.

Results Achieved

By modernizing the existing conveyor technology, the center achieved an impressive reduction in energy consumption—nearly 50%. Focusing on key component upgrades helped lower maintenance and investment costs while maintaining high operational performance:

• Up to 48% energy savings while sustaining a throughput of 4,000 parcels
• Significant noise reduction, creating a quieter and more employee-friendly work environment
• Optimized maintenance costs and extended system lifespan
• Reduced CO₂ emissions, contributing to sustainability goals
  

Why Upgrade Conveyor Systems with ETEK Intralogistics

• Deep technical expertise in retrofitting and optimizing existing equipment
• Tailored solutions for each warehouse model—no need for full system replacement
• Deployment of world-leading energy-efficient drive technologies
• Lower investment costs, higher efficiency, and stable, reliable operations

Are you looking to reduce energy consumption and upgrade technology while keeping your current conveyor system?

Contact ETEK Intralogistics today for expert consultation on the most suitable conveyor upgrade solution for your business.