These shifts can create real challenges for line stability.
“ We’ re seeing a much wider range of packaging formats, and many of them are inherently less stable,” Boers explains.“ Sleek or slim cans, for example, have a smaller footprint than traditional ones. That means less contact with the conveyor surface and a higher risk of tipping. This is especially true during dry running or when moving across conveyor gaps.”
At the heart of many of these stability issues is the space between conveyor segments— known as the dead plate.
“ Smaller products struggle more with large transfer gaps,” says Boers.“ It’ s not just about tipping, but also preventing jams, reducing misalignment, and maintaining throughput.”
To address this, Regal Rexnord has introduced new belts such as the 1533 Series LBP( Low Back Pressure) MatTop™ Chain, a 15mm pitch modular belt featuring integrated rollers directly within the belt surface. This innovation allows for tighter transfers without dead plates, enabling smooth motion even for narrow or unstable packs.
Meanwhile, the Rexnord 1540 Curve System with tangential belt operation ensures a consistent very small transfer zone across the entire belt width – something not all curve systems can guarantee.
“ With many more traditional designs, the transfer gap can widen significantly near the belt edges,” Boers says.“ Ours stays uniform, which is critical for line layout flexibility and pack integrity.”
For Regal Rexnord, these developments are part of a broader shift toward smaller pitch and more densely engineered modular belts.
These small adjustments play a key role in helping producers maintain line performance despite any reduced packaging stability caused by modern designs.
Dry-running that delivers
Sustainability is another key driver behind packaging changes, and not just in the materials themselves. Many beverage plants are transitioning to dry-running conveyor systems, minimizing the use of water- and soap-based lubrication to reduce environmental impact, simplify wastewater treatment, and improve workplace hygiene and safety by keeping production floors clean and dry.
Dry-running, however, places greater demands on conveying components. With no lubricants to reduce friction or ease product flow, chains must offer low-friction surfaces, high wear resistance, and easy cleanability.
While cardboard clips are more eco-friendly and shelf-efficient than traditional shrink-wrapped packaging, they can also introduce new operational headaches on the production line.
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