Material Handling Devices in Food Processing: Types and Uses

In any food processing plant, raw materials and finished products need to move – horizontally across the floor, vertically between levels, or through enclosed pipelines to the next stage of production. The devices that make this movement possible are broadly called material handling devices. Choosing the right one directly affects plant efficiency, product quality, and food safety. This post breaks down the major types of material handling devices used in food processing – conveyors and elevators – along with their working principles, best-use scenarios, and the factors that guide their selection.

Why material handling matters in food processing 🔗

Food processing involves multiple stages: receiving, sorting, cleaning, processing, packaging, and storage. At each transition, materials need to be transported quickly and safely. Manual handling is slow, inconsistent, and introduces contamination risks. Mechanical material handling devices solve these problems by automating the flow of ingredients and products through the plant. They reduce labour costs, minimise human contact with food (a critical hygiene requirement), and keep production lines running without bottlenecks. According to JM Industrial, automated conveyors maintain continuous product flow, lower idle time, and help meet the strict sanitation standards set by agencies like the FDA and USDA.

Conveyors: moving materials horizontally and on inclines 🔗

Conveyors are the most widely used category of material handling devices in food plants. They transport materials horizontally or at moderate inclines between different processing stations. Several types exist, each designed for specific materials and conditions.

Belt conveyors 🔗

A belt conveyor uses a continuous loop of flexible material – typically food-grade rubber, fabric, or modular plastic – stretched over rollers or a flat bed. The belt moves in one direction, carrying products along with it. Belt conveyors are the workhorse of the food industry. They handle everything from raw fruits and vegetables to packaged goods, baked items, and frozen foods. As noted by Processing Magazine, they typically have the lowest initial capital cost among all conveying solutions, which makes them extremely popular. They are also the preferred choice when significant elevation changes are needed (beyond about 10 degrees of incline). However, their total cost of ownership can rise significantly due to high maintenance and sanitation expenses, especially when compared to vibratory or horizontal motion conveyors over a three-year period.

Best suited for: packaged goods, solid products, bakery items, produce, frozen foods, and applications requiring precise product placement.

Roller conveyors 🔗

Roller conveyors consist of a series of rotating cylindrical rollers mounted in a frame. Products placed on the rollers move forward either by gravity (gravity roller conveyors) or by motorised rollers. They are commonly used in food plants for moving boxed, crated, or packaged goods – especially at the end of a production line where items need to be sorted, accumulated, or transferred to storage. According to JM Industrial, roller conveyors are efficient for handling heavy or boxed products and require relatively low power.

Best suited for: packaged or boxed food products, end-of-line handling, and warehouse transport.

Screw conveyors 🔗

A screw conveyor (also called an auger conveyor) consists of a helical screw blade rotating inside a U-shaped trough or a cylindrical tube. As the screw turns, it pushes material forward from the inlet to the discharge point. Screw conveyors are widely used for transporting granular and powdery materials like flour, sugar, starch, grains, and spices. They offer controlled and uniform flow, are compact in design, and are typically less expensive than other conveyors of similar length and capacity. One key specification is that the standard pitch – the distance between successive screw threads – is equal to the screw’s diameter. For instance, a 10 cm diameter screw will have a 10 cm pitch.

Limitations: They can cause material degradation with fragile products and require regular maintenance of the screw blade and bearings.

Best suited for: dry bulk ingredients like flour, sugar, animal feed, and grains over short to moderate distances.

Vibratory conveyors 🔗

Vibratory conveyors move materials along a stainless steel trough or pan using controlled vibrations. The vibration can be generated mechanically (high amplitude, low frequency) or electromagnetically (low amplitude, high frequency). The diagonal harmonic motion lifts and advances the product gently along the conveyor bed. These conveyors are a standout choice in food processing because of their sanitary design. Their smooth, one-piece pans have no belts, pulleys, or crevices where food particles can accumulate. As highlighted by PFI Conveyors, the minimal number of moving parts reduces contamination points compared to belt conveyors. Beyond simple transport, vibratory conveyors can also perform screening, dewatering, spreading, and feeding – multiple functions in a single machine.

Best suited for: fragile or sticky materials like nuts, candies, frozen vegetables, chips, dried fruits, and products needing gentle handling or additional processing steps like coating removal or sizing.

Flight conveyors 🔗

Flight conveyors (also called drag conveyors or chain conveyors) use a series of flat plates or “flights” attached to a chain that drags materials through an enclosed trough. They are effective for moving bulk materials like grains, seeds, and pellets in a controlled manner. Flight conveyors can operate both horizontally and at inclines, and they offer good flow control. However, they tend to require more regular maintenance than some other types and may not be the most energy-efficient option for very long distances.

Best suited for: bulk grains, seeds, pellets, and situations requiring enclosed, dust-free transport of heavy loads.

Elevators: moving materials vertically 🔗

When materials need to go up – from a ground-level receiving area to an elevated processing floor, or from one production level to another – elevators are the devices of choice. They are designed specifically for vertical transport and come in several configurations.

Bucket elevators 🔗

Bucket elevators are among the most common vertical transport devices in food processing. They consist of a series of buckets attached to a belt or chain that loops vertically between a boot (bottom) section and a head (top) section. Material is scooped into the buckets at the bottom, carried upward, and discharged at the top as the buckets tip over. The spaced-bucket centrifugal discharge type is the most commonly used configuration for grain handling. According to PPM Technologies, bucket elevators can handle a wide range of dry, free-flowing products – including nuts, snack foods, cereals, and pet foods – at flow rates up to approximately 2,000 cubic feet per hour and heights of up to 30 feet. They require limited horizontal space, and because the conveying path is fully enclosed, operation is dust-free and relatively quiet.

Best suited for: vertical transport of grains, flour, powders, cereals, snack foods, and other dry bulk materials.

Magnetic elevators 🔗

Magnetic elevators use magnetic force to transport materials that are ferromagnetic – meaning they contain iron or steel. In food processing, their primary application is not so much moving food products themselves but rather removing metal contaminants from product streams or transporting metal containers (like cans) vertically. They are a specialised device used where the material or container responds to magnetic fields.

Best suited for: handling metal containers, cans, or ferromagnetic components in food packaging lines.

Flight elevators 🔗

Flight elevators work on a principle similar to flight conveyors but oriented vertically. Flat plates or flights attached to a chain push or drag material upward through an enclosed casing. They are used for bulk materials that need vertical lifting in enclosed environments. While they can handle heavy loads and provide controlled flow, they may require more maintenance than bucket elevators due to the friction involved.

Best suited for: bulk grains, seeds, and granular materials requiring enclosed vertical transport.

Pneumatic elevators (pneumatic conveyors) 🔗

Pneumatic elevators – more commonly referred to as pneumatic conveying systems – use air pressure or vacuum to move materials through enclosed pipelines. They can transport products horizontally, vertically, or around bends, making them extremely flexible in terms of routing. There are two main types: dilute phase systems (low pressure, high velocity – suited for lighter, non-abrasive materials like flour and sugar) and dense phase systems (high pressure, low velocity – ideal for fragile or abrasive materials like coffee beans, cereal, and cocoa).

Pneumatic systems offer several compelling advantages for food processing. As explained by Progressive Products, they have fewer moving parts compared to mechanical conveyors, which makes them easier to maintain and safer for operators. The fully enclosed pipeline design keeps dust contained and protects the product from environmental contamination – a critical factor for food hygiene. They also take up less floor space than mechanical alternatives, since the pipelines can be routed overhead or around existing equipment. According to Dover MEI, pneumatic systems also reduce the risk of cross-contamination between batches, which is essential in plants handling multiple allergens or ingredients.

Limitations: They can consume more energy than mechanical conveyors over short distances and may not be suitable for wet or highly cohesive materials.

Best suited for: powdery and granular materials like flour, sugar, spices, milk powder, cocoa, coffee, and grains – especially where hygiene, dust control, and flexible routing are priorities.

How to select the right material handling device 🔗

No single conveyor or elevator works for every situation. The selection depends on a combination of factors that plant engineers and managers must evaluate carefully.

Type of material being handled 🔗

The physical properties of the material – whether it is dry, wet, powdery, granular, fragile, sticky, or abrasive – are the starting point. For example, belt conveyors handle solid and packaged items well, screw conveyors work for powders and granules, vibratory conveyors are ideal for fragile items, and pneumatic systems excel at transporting fine powders. As JM Industrial notes, belt conveyors work best for packaged or solid products, while screw, vibratory, or bucket conveyors are better for powders, grains, or fragile items.

Direction and distance of transport 🔗

Horizontal movement over long distances is typically best handled by belt or flight conveyors. Short-distance horizontal movement of bulk materials works well with screw conveyors. Vertical transport calls for bucket elevators or pneumatic systems. If the route involves many bends and changes in direction, pneumatic conveyors offer unmatched flexibility.

Required capacity and speed 🔗

Each device type has a different throughput capability. Bucket elevators can move large volumes vertically. Belt conveyors can be scaled in width and speed for high throughput. Vibratory conveyors, especially electromagnetic types, allow precise speed adjustment for accurate metering and feeding applications.

Hygiene and food safety requirements 🔗

In food processing, sanitation is non-negotiable. Devices must be easy to clean, made from food-grade materials (usually stainless steel), and designed to prevent product buildup and bacterial growth. Vibratory conveyors and pneumatic systems generally score highest on hygiene due to their enclosed or smooth, belt-free designs. Belt conveyors, while versatile, can present sanitation challenges at belt-to-roller contact points.

Available space and plant layout 🔗

Floor space is often limited in food plants. Pneumatic systems and bucket elevators are compact vertical solutions. Screw conveyors have a small footprint for horizontal transport. Belt conveyors may need more room for supports, rollers, and return paths.

Cost considerations 🔗

Both initial investment and long-term operating costs matter. Belt conveyors have low upfront costs but potentially high maintenance expenses. Vibratory and horizontal motion conveyors may cost more initially but often have a lower total cost of ownership over time. Pneumatic systems can be more economical to maintain due to fewer moving parts, but energy costs may be higher for certain applications.

A quick comparison of major material handling devices 🔗

To summarise the key differences: belt conveyors are versatile and affordable upfront, best for solid and packaged goods. Roller conveyors handle boxed products with low power needs. Screw conveyors are compact and precise for powders and granules. Vibratory conveyors offer gentle, hygienic handling for fragile and bulk items. Flight conveyors move heavy bulk materials in enclosed paths. Bucket elevators efficiently lift dry bulk materials vertically. Pneumatic systems provide enclosed, flexible, hygienic transport for fine powders and granules. Each device addresses a specific set of challenges – and many food plants use a combination of these systems working together across the production line.

What do you think? If you were designing a food processing plant from scratch, which material handling device would you prioritise first – and how would the type of food product you’re processing influence that decision?

References

1. https://www.jmindustrial.com/blog/industrial-conveyors-for-food-processing-lines/
2. https://www.processingmagazine.com/material-handling-dry-wet/conveyors/article/53064872/choosing-the-ideal-conveyor-for-your-food-product
3. https://www.pficonveyors.com/resource/common-vibratory-conveyor-applications/
4. https://ppmtech.com/products/material-handling/bucket-elevators/
5. https://blog.progressiveproductsinc.com/benefits-pneumatic-conveying-food-beverage-industry
6. https://dovemei.com/how-pneumatic-conveying-systems-improve-food-safety-and-efficiency/