The secret of double conveyor line space optimisation with 1 machine for double conveyor lines

What is the nature of a two-lane conveyor line? Why is it able to break through spatial limitations?

Double lane conveyor line throughUpper and lower double layer structure or parallel channel designThe first step is to realise the synchronous conveying and refluxing cycle of materials in a single machine. The core breakthrough lies in the use ofVertical space alternative to horizontal expansion--When the traditional single-line layout requires lateral extension of workstations, the dual-channel line reduces the floor space by more than 50% by superimposing conveying layers. For example, after adopting the upper and lower double-channel line in the auto parts workshop, it can complete the conveying task of 10m×8m in the original 5m×8m area, which directly releases 30% floor space.

How can 1 machine realise dual-line conveying? Where is the key technology?

​The secret lies in the synergy of three core technologies::

  1. ​Dynamic Floor Height Adjustment System​
    The layer spacing (800-1500mm adjustable) is controlled by servo motor to adapt to different volume materials. For example, when the logistics sorting centre handles mixed shipments, the upper layer conveys home appliance boxes (height > 1m), and the lower layer conveys document bags in parallel, avoiding the need to set up a separate sorting line for small pieces.
  2. ​Intelligent Path Switching Module​
    Connection components are made ofPluggable guide design::

    • When the connecting plate is locked in the double-channel position, the material is transferred from the upper layer to the lower layer through the guide groove, forming a closed-loop reflux.
    • Immediate restoration of single-line independent operation after removal of the connection plate
      Tests at an electronics factory in Kunshan have shown that the production line switching time has been reduced from 4 hours to 15 minutes for traditional modifications.
  3. ​Compact drive layout​
    Dual-powered drums share 1 set of inverter motors, through theUniversal Joint Drive Shaft Synchronised Drive Dual Channel(see structure below), saving 35% compared to the traditional two-wire split motor solution.

Which industries need space optimisation the most? How can specific programmes be implemented?

▍制造业：重型部件车间的空间突围

​sore point: Wide aisle is required for conveying large machinery parts (conventional >3m), but the distance between the plant columns is only 6m.
​programme::

  • adoptionZ-type double-channel chain plate lineThe upper level conveys rough parts (load capacity 1.5t/m) and the lower level returns finished products.
  • Integrated hydraulic steering module at corners, replacing traditional 90° turners
    A construction machinery plant was remodelled with 2 new reflow lines in a 480 m² workshop, increasing capacity by 40%.

ralph lauren food processing: a win-win situation for health and safety and space efficiency

​sore pointClean aisles need to be reserved for 1.5m safety distance, squeezing the space for equipment layout.
​prescription::

  • Double-layer stainless steel PU belt structure: the upper layer conveys the packaged products, and the lower layer conceals the CIP cleaning pipeline.
  • Hot lye circulation system embedded in the rack column, eliminating the need for external piping.
    Guangdong condiment enterprises measured show that the design saves the clean area area of 60%, and through the HACCP certification.

What happens when you ignore space optimisation? The cost comparisons are staggering

Case Comparison: Single Line Extension vs Dual Channel Modification

norm Traditional single-line expansion programme Two-channel conveying line programme Optimisation effects
footprint (of a building, piece of equipment etc) Additional 120m2 required (monthly rent ￥24,000) Zero additional land Save ￥288,000 per year
Equipment inputs 2 independent conveyor lines (￥760,000) 1 dual-channel system (¥680,000) Cost reduction 10.5%
power consumption Dual motor 22kW-h Single motor + gimbal 15kW-h Save ￥37,000 on annual electricity bill
Retrofit time Production line switchover 4 hours/time Guide channel adjustment 15 minutes/times 16 times more efficient

Data source: Kunshan Xinyi Guomao Automation Technology Renovation Case (2024)

Factory of the future must-have: the progression from single line to double lane

​Step 1: Diagnose space bottlenecks​
Measurement of shop column spacing, pickup heights, and equipment interference zones is preferred atHeight >4.5mRegional deployment of dual lane lines (e.g., raw material storage to filling line transition area).

​Step 2: Modular and phased implementation​

Image Code
graph LR
A[Basic version] -->|Fixed Height Dual Channel Line| B[Space Utilisation +50%]
A --> C[Intelligent interface reserved]
D[Upgraded] -->|PlusRFIDSorting E[Dynamic path switching]
D -->|Integrated Energy Monitoring F[O&M costs-30%]


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Fixed floor height double track line




Add RFID sorting




Integrated Energy Monitoring




basic version




Space Utilisation +50%




Reserve Smart Interface




updated version




Dynamic path switching




O&M Costs - 30%




​terminal form::

For example, a smart factory in HunanStereo Matrix System: 4-storey double-channel line + AGV connection, achieving the logistics throughput of a traditional 5,000m2 factory in 2,000m2.


When peers are still anxious for land acquisition and expansion, double channel conveying line is using vertical revolution to reconstruct the production boundary - it is never a choice, but the survival of site-constrained enterprises must choose.

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