Free roller conveyor Manufacturer in India
Free Roller Conveyor Manufacturer
in Ghaziabad, Delhi NCR & India
Gravity-driven roller conveyor systems — the most cost-effective solution for carton, box, and crate handling in warehouses, logistics hubs, FMCG packaging lines, and e-commerce fulfilment centres. No motor. No electricity. No complex controls. Roller diameter 38–89 mm. Frame widths 300–1,200 mm. Load capacity up to 500 kg/m. Custom-built in Ghaziabad. PAN India installation since 2007.
What Is a Free Roller Conveyor — and Why Is It the Most Widely Used Warehouse Conveyor in India?
Neo Conveyors is a specialist free roller conveyor manufacturer in India since 2007. A free roller conveyor — also called a gravity roller conveyor — uses rollers that spin freely on their own shafts. Products placed on the roller surface move by gravity on a slight downward slope, or by manual push on a flat section. There is no motor, no electricity, and no control panel required. The sealed ball-bearing rollers simply rotate as products pass over them — providing smooth, low-friction material movement at the lowest possible capital and operating cost of any conveyor type. This is why free roller conveyors are the single most commonly specified conveyor system in Indian warehouses, dispatch areas, packaging lines, and FMCG distribution centres. Neo Conveyors designs every system around your carton or product dimensions, load weight, line length, and floor layout — manufactured at our Ghaziabad plant and installed by our own team across India. For higher-speed or motorised operation, see our powered roller conveyor → For the full roller conveyor range: roller conveyor manufacturer India →
Free Roller Conveyor — Live Warehouse Operation
Watch a Neo Conveyors gravity roller conveyor system in real warehouse operation — smooth gravity-driven carton flow, accumulation zones, and zero-power material movement at the customer's facility.
▶ Free Roller Conveyor — Gravity Warehouse Carton Handling | Neo Conveyors
▶ Neo Conveyors — Manufacturing & Installation Overview
How a Gravity Roller Conveyor Works — Configuration Types & Roller Selection
Understanding the gravity flow principle and roller selection criteria ensures you get the right conveyor for your product and plant layout the first time — without over-engineering or under-specifying.
Configuration Type Selection Guide
Roller diameter, material, and pitch are selected based on product weight, base rigidity, and operating environment. Configuration type is selected based on your plant layout and throughput requirement.
Standard Configuration
Straight inline roller conveyor — the most common warehouse configuration for carton transfer, dispatch areas, and accumulation zones.
Best for: Dispatch · Picking · Packaging
Directional Change
Tapered rollers allow the product to follow a curved path — ideal for warehouse layouts where a 30°, 45°, or 90° turn is required without a powered transfer unit.
Best for: Layout turns · Space saving
Telescopic / Flexible
Scissor-type expandable frame allows the conveyor to extend or compress — used at truck loading docks, loading bays, and seasonal fulfilment capacity expansion.
Best for: Loading docks · Flexible lines
Hygienic Roller Conveyor
Stainless steel 304/316 frame and roller shells with food-grade sealed bearings for cold storage, food processing, and pharmaceutical environments.
Best for: Food · Cold storage · Pharma
High Load — Pallet Grade
89 mm diameter thick-walled rollers with heavy-duty frame for crates, pallets, and drums — load capacity up to 500 kg/m for industrial and logistics applications.
Best for: Pallets · Crates · Heavy loads
Ultra-Lightweight Products
Skate wheels instead of full rollers — ideal for very light products, sacks, and irregular-base items where full rollers would create excessive friction or product snagging.
Best for: Light cartons · Sacks · Bags
Straight gravity roller with 50 mm MS rollers is the most commonly specified configuration for Indian warehouse and FMCG dispatch applications. Expandable models are standard for truck loading dock integration.
How Gravity Roller Conveyor Flow Works — 5 Key Principles
Slope & Gravity Drive
The conveyor frame is set at a slight downward slope — typically 2° to 5° (35–90 mm per metre). Products placed on the rollers accelerate under gravity and move along the conveyor without any motor or manual push. Slope is calculated per product weight and base friction.
Roller Rotation
As the product moves forward, it contacts each roller and causes it to rotate on its sealed ball-bearing shaft. The low-friction sealed bearings allow rollers to spin freely with minimal resistance — giving products smooth, consistent forward movement.
Roller Pitch — Always 3 Rollers Under Every Product
The centre-to-centre distance between rollers (roller pitch) must be set so that the smallest product rests on at least 3 rollers at any point. Our engineers calculate the correct pitch for your product before manufacture — preventing tipping or jamming.
Natural Accumulation
When a product reaches the end of the roller section and is stopped — by an operator, a gate, or another product — subsequent products accumulate behind it naturally. This built-in accumulation zone is one of the key advantages of gravity roller conveyors over belt conveyors.
Manual Push on Flat Sections
Where a slope is not possible due to floor height constraints, the conveyor runs flat and products are manually pushed from one station to the next. The low-friction sealed bearings make manual pushing very light — significantly reducing operator fatigue over full-shift operation.
Free Roller Conveyor — Technical Specifications
All systems are custom-designed from your product dimensions, load weight, conveyor length, and plant layout. Every order begins with a roller pitch calculation and layout drawing by our engineers at no charge.
| Roller Diameter | 38 mm / 50 mm / 63 mm / 76 mm / 89 mm — as per load |
| Roller Pitch | 75 mm to 300 mm — calculated per smallest product size |
| Frame Width (Between Frames) | 300 mm to 1,200 mm — custom as per product width |
| Conveyor Length | As per plant layout — no standard limit per section |
| Load Capacity | Up to 500 kg per metre (heavy-duty frame configuration) |
| Roller Shell Material | MS / Galvanised Steel / SS 304 / SS 316 / PVC |
| Frame Material | Mild Steel (MS) or Stainless Steel (SS) |
| Roller Bearing | Sealed ball bearing — grease-filled for long life |
| Roller Wall Thickness | 2.0 mm / 2.5 mm / 3.2 mm — as per load |
| Frame Finish | Powder Coated / Painted / Food Grade / HDG |
| Conveyor Legs | Fixed height or adjustable height with bolt adjustment |
| Operating Slope | 2° to 5° for gravity flow (35–90 mm/m) — engineered per product |
| Drive Type | Gravity — no motor, no electricity required |
| Special Options | Curved sections / Expandable / Guard rails / Slope stops |
Slope Guide — Gravity Flow by Product Type
| Product Type | Approx. Slope Needed | Notes |
|---|---|---|
| Heavy cartons > 15 kg | 2° – 3° (35–55 mm/m) | Light slope sufficient |
| Standard cartons 5–15 kg | 3° – 4° (55–70 mm/m) | Standard specification |
| Light cartons < 5 kg | 4° – 5° (70–90 mm/m) | Steeper slope needed |
| Plastic totes / crates | 2° – 4° (35–70 mm/m) | Depends on base friction |
| Flat or manual push | 0° — flat | Operator pushes product |
Indicative only. Slope is calculated per product weight, base material, and roller shell material. Our engineers provide exact slope recommendation for your products before manufacture.
What Products Can Free Roller Conveyors Handle — and What They Cannot
Free roller conveyors are engineered specifically for products with flat, rigid bases. Selecting the wrong conveyor for your product is the most common and costly specification error — this guide prevents it.
- Corrugated cartons & cardboard boxes
- Plastic totes and stackable crates
- Wooden crates and pallets
- Metal trays and baking trays
- Fibre drums and plastic drums
- Rigid plastic containers
- Packaged food boxes (flat base)
- E-commerce parcels in outer cartons
- Automotive parts in rigid trays
- FMCG secondary packaging cases
- Glass jars in outer cartons
- Heavy palletised loads (heavy-duty rollers)
Every product must always rest on at least 3 rollers at any point. Our engineers calculate the correct pitch for your smallest product before manufacture.
- Bags, sacks, and flexible packaging (no rigid base)
- Loose bulk material or powder
- Round bottles or cans without a tray
- Very light products (<500g) — insufficient gravity force
- Steep inclines above 15° — products accelerate uncontrollably
- High-speed automated production at fixed speed
- Products requiring controlled, timed delivery
- Fragile items sensitive to roller impact (use belt conveyor)
For bags and irregular-base products: see our belt conveyors →
For controlled-speed automated lines: see our powered roller conveyor →
For assembly production lines: see our assembly line conveyors →
✅ Suitable Products at a Glance
Why Free Roller Conveyors Are the Most Widely Used Warehouse Conveyor in India
Every warehouse, dispatch area, and packaging line in India uses gravity roller conveyors as the backbone of its material flow system — not by convention, but because no other conveyor type delivers this combination of simplicity, reliability, and operating cost.
Zero Electricity — Zero Power Bill
Gravity does the work. No motor, no drive panel, no VFD, no electrical installation, and no electricity consumption — ever. The lowest operating cost of any conveyor type, every shift, every year of service life.
Lowest Maintenance Cost
The only moving parts are the sealed ball bearings inside each roller. When a roller bearing fails after years of service, the single roller is replaced in under 5 minutes without dismantling the conveyor — zero downtime, zero specialist labour required.
Completely Flexible Layout
Straight sections, curved sections, expandable sections, fixed or adjustable height legs — roller conveyors adapt to any warehouse floor plan, any building column layout, and any future rearrangement of your facility.
Natural Accumulation Buffer
Products naturally queue and accumulate on roller conveyors without motor overload, belt jam, or system fault — creating a built-in buffer zone between stations that absorbs timing variations in manual picking and packing operations.
Lowest Capital Cost
No motor, no gearbox, no control panel, no electrical installation — the gravity roller conveyor is the lowest-cost conveyor system to purchase, install, and commission. ROI is typically achieved within 2–4 months of replacing manual carrying.
Expandable As You Grow
New sections can be added to an existing gravity roller system at any time — at any point along the line. Roller conveyors grow with your warehouse throughput without requiring a new system or full replacement.
Free Roller Conveyor vs Powered Roller Conveyor — Which Is Right for Your Warehouse?
The single most important conveyor selection decision in a warehouse or logistics facility. Understanding when gravity is enough — and when you need a motor — prevents costly over-specification or operational problems after installation.
| Factor | ✅ Free Roller Conveyor | Powered Roller Conveyor |
|---|---|---|
| Drive system | Gravity — no motor, no power | Electric motor — controlled speed |
| Electricity cost | Zero — no power consumption | Minimal — efficient motor drives |
| Capital cost | Lowest of any conveyor type | Higher — motor, drive, control panel |
| Speed control | None — slope angle determines speed | Full VFD speed control |
| Flat floor operation | Requires slope or manual push | Runs on flat floor at set speed |
| Automated timing | No timed delivery — natural flow only | Timed, controlled product delivery |
| Accumulation | Natural — zero effort accumulation | Requires zero-pressure accumulation rollers |
| Maintenance | Extremely low — no motor components | Low — simple motor and drive service |
| Installation complexity | Minimal — no electrical installation | Requires electrical connection and panel |
| Best application | Warehouse picking, dispatch, accumulation, loading bays | Production integration, e-commerce sorters, flat-floor automation |
| Typical industries | Warehouse, FMCG dispatch, courier, manual packaging | E-commerce fulfilment, assembly, automated production |
Need motor-driven roller conveying? See our Powered Roller Conveyor → | For belted flat surface conveying: Roller on Bed Belt Conveyor → | Full comparison: Roller Conveyor Manufacturer India →
Free Roller Conveyor — Custom Configurations We Engineer
Every gravity roller conveyor is custom-designed to your product size, load, and plant layout. Standard configurations that Neo Conveyors engineers and manufactures are listed below — contact us with your carton dimensions, floor plan, and throughput requirement.
📏 Straight Gravity Roller
Standard configuration for warehouse picking zones, dispatch lines, and packaging transfer. Available in any width from 300 to 1,200 mm and any length.
↩️ Curved Roller Conveyor
Tapered rollers forming 30°, 45°, 60°, or 90° bends — allows directional change within a gravity flow line without a powered transfer unit.
↔️ Expandable Roller Conveyor
Scissor-type flexible frame extends and compresses — ideal for truck loading docks, mobile picking lines, and temporary throughput capacity expansion.
🍽️ Stainless Steel / Food Grade
SS 304/316 frame and roller shells with food-grade sealed bearings — for cold storage, food processing, dairy, and pharmaceutical environments.
🏋️ Heavy Duty Roller Conveyor
89 mm diameter, 3.2 mm wall rollers with heavy-duty frame — for crates, pallets, and drums up to 500 kg/m load capacity in industrial settings.
🛞 Skate Wheel Conveyor
Individual skate wheels replacing full rollers — ideal for very light cartons, sacks, and irregular-base products where full rollers create too much friction.
📐 Adjustable Height Legs
Bolt-adjustable leg height allows conveyor level to match existing workstations, palletising points, or loading dock heights at different facilities.
🚧 Guard Rails & Slope Stops
Side guard rails prevent product falling off during gravity flow. Slope stop gates at zone ends control product accumulation and release in batch picking operations.
Industries Using Free Roller Conveyor Systems
Every industry that stores, dispatches, or packages products in cartons, boxes, or crates uses gravity roller conveyors as the foundation of its material flow system. Here is how each major sector uses them and what application-specific requirements drive the configuration.
🏭Warehousing & Logistics
Goods-in receiving lines, picking zone to packing bench transfer, dispatch accumulation lines, and truck loading bays. Expandable models at loading docks extend from fixed line to truck interior for zero-lift carton loading by operators.
Warehouse roller conveyor → Powered Rollers🛒E-Commerce Fulfilment
Order picking transfer from pick zone to packing station, outbound sorting accumulation, and despatch area gravity lanes. Low capital cost allows full-facility roller coverage — critical in capital-intensive fulfilment start-ups.
E-com parcel conveyor → Powered Rollers🧴FMCG Packaging Lines
Carton transfer between packaging machine discharge and case packing or palletising stations. Natural accumulation buffer between variable-speed packaging machines and manual case packing — absorbs machine timing variation without line stoppage.
FMCG packaging conveyor → Assembly Line📬Courier & Parcel Handling
Parcel transfer from inbound scanning to sortation areas and from sorting to dispatch lanes. Zero power consumption is critical at high-throughput courier hubs where electricity cost per parcel directly impacts profitability.
Parcel gravity conveyor → Roller Conveyors🍫Food & Beverage
Secondary packaging case transfer in food manufacturing and beverage bottling plants. SS 304/316 and food-grade configurations for cold storage and hygiene-critical environments. No motor means no heat generation near food products.
Food grade roller conveyor → Belt Conveyors🔩Manufacturing & Assembly
Work-in-progress transfer between assembly stations, sub-assembly accumulation zones, and finished goods transfer to palletising. Gravity flow between stations allows each operator to pull work at their own pace without motor synchronisation.
Assembly transfer conveyor → Assembly Line🏗️Distribution Centres
Inter-zone carton transfer between receiving, storage, picking, packing, and despatch. Multiple gravity roller lanes allow concurrent product flow across high-throughput distribution operations at minimal infrastructure cost.
DC roller conveyor → Telescopic Conveyor💊Pharma & Cold Chain
SS 304/316 food-grade roller conveyors for temperature-controlled pharmaceutical cold storage and clean-room material transfer. No motor means no heat or electromagnetic interference near sensitive pharmaceutical products.
Pharma roller conveyor → Inspection ConveyorsShare Carton Size & Layout — Get Free Roller Conveyor Design
Tell us your carton or product dimensions, weight, conveyor length, number of sections, required slope, and any curves or level changes. Our engineers will design the correct roller pitch, roller diameter, and frame specification — and provide a detailed quotation free of charge.
Free Roller Conveyor — Real Installations by Neo Conveyors
Three representative projects — e-commerce dispatch, FMCG packaging, and manufacturing — showing the engineering decisions and operational results from each installation.
Gravity Dispatch Conveyor — 45 m, 3 Zones, Expandable Loading Dock
A growing e-commerce fulfilment operator needed to eliminate manual carton carrying from their packing stations to truck bays — a 45 m distance, 600–800 cartons per shift, floor-level operations on a slight natural slope. Previous manual process required 6 handlers per shift and was causing back-strain incidents.
Neo Conveyors designed a gravity roller conveyor system — 600 mm wide, 50 mm MS rollers at 100 mm pitch, 3° slope, three straight sections linked by 90° curved segments, expandable roller conveyor at each of 3 loading dock bays. MS powder-coated frame with bolt-adjustable legs matched to existing floor levels.
Carton Accumulation & Transfer Line — 28 m, 4 Packaging Stations
An FMCG secondary packaging facility needed a gravity accumulation system to buffer cartons between 4 packaging machine discharge points and a central case-packing station — eliminating operator waiting time during machine speed variation and short stoppages. Manual carrying had created an uncontrolled bottleneck at the case-packing table.
Neo Conveyors installed four parallel gravity roller lanes — 400 mm wide, 50 mm GI rollers at 100 mm pitch, 4° slope, each 7 m long, converging at a manual merge point before the case-packing station. Slope stops at each machine discharge allowed individual batch release.
Assembly WIP Transfer — 22 m, 6 Workstations, Heavy-Duty Rollers
An auto components manufacturer needed to transfer partially assembled sub-assemblies in metal trays between 6 workstations along a 22 m line — tray weight up to 35 kg per unit, 3 shifts of continuous operation. Previous manual hand trolley system was slow, fatiguing, and creating inter-station timing problems.
Neo Conveyors designed a heavy-duty gravity roller line — 800 mm wide, 76 mm diameter 3.2 mm wall thickness MS rollers, 150 mm pitch, 2° slope with slope stops at each station, heavy-duty MS frame with 6-bolt adjustable legs. Load capacity 500 kg per metre across full 22 m length.
Free Roller Conveyor — Industrial Buyer FAQs
Why Choose Neo Conveyors as Your Free Roller Conveyor Manufacturer?
Product-First Engineering — Not Catalogue Selling
Every roller conveyor design starts with your carton or product dimensions — roller pitch calculated from your smallest product, slope calculated from product weight. You receive a layout drawing before manufacture. We don't sell off-the-shelf sizes that may not suit your product.
Full Conveyor Range — One Supplier
Free roller, powered roller, assembly line, belt, screw, and bucket elevator — all manufactured in-house. One supplier for your entire warehouse and plant material handling system — from receiving dock to despatch bay. See the full product range →
In Stock — Short Lead Times
Standard MS and GI roller stock maintained at our Ghaziabad facility. Most standard gravity roller conveyor orders can be fabricated and dispatched within 7–14 days — significantly faster than multi-week catalogue lead times from distributors.
PAN India — Our Own Engineers Install
Installation and levelling by Neo Conveyors' own team — including slope setting, roller pitch verification, and joint alignment. No third-party erection contractors. See our project gallery →
AMC & Spare Roller Support
Replacement rollers and bearings available for every system we supply. Annual Maintenance Contracts covering roller inspection, bearing replacement, and frame alignment available after installation. Technical support →
Competitive In-House Pricing
Manufactured at Ghaziabad — no middleman, no distributor margin. Transparent quotations with full engineering data provided to every buyer. 1,000+ installations across warehousing, FMCG, e-commerce, food, and manufacturing since 2007. About Neo Conveyors →
Learn More — Roller Conveyor & Warehouse Material Handling Guides
Roller Conveyor Complete Guide — Free vs Powered vs Belt
How to select the right roller conveyor type for your warehouse, packaging line, or manufacturing plant — with full comparison tables.
Gravity Roller Conveyor Design Guide — Slope, Pitch & Roller Selection
How to calculate the correct slope, roller pitch, and roller diameter for your product — the technical decisions that determine whether a gravity roller system works in practice.
Warehouse Conveyor Systems — Complete Guide for Indian Warehouses
How to specify roller conveyors, belt conveyors, and sorting systems for your warehouse — from goods-in to despatch bay.
E-Commerce Fulfilment Conveyor Systems — India Guide
How to design a cost-effective gravity and powered roller conveyor system for Indian e-commerce fulfilment centre operations.
Conveyor Comparison — Roller vs Belt vs Chain for Warehouses
When to use a roller conveyor, when to use a belt conveyor, and when neither is the right answer — the complete comparison for warehouse material handling buyers.
All Conveyor Blogs & Technical Guides
Browse all Neo Conveyors technical articles, installation guides, and warehouse material handling resources.
Free Roller Conveyor Manufacturer Across India
Neo Conveyors supplies and installs gravity roller conveyor systems for warehouses, logistics hubs, FMCG plants, e-commerce fulfilment centres, and packaging facilities across all major industrial cities and states in India — from our Ghaziabad manufacturing facility.
Get a Free Roller Conveyor Design — Carton Size to Layout in 24 Hours
Share your carton or product dimensions, weight, number of sections, conveyor length, floor layout, and any slope or level change constraints. Our engineers will calculate the correct roller pitch, slope, and frame specification — and provide a full no-obligation quotation within 24 hours.
