While no two farms are exactly alike, here are some common types of conveyors and material handling systems used in vertical farms. We've arranged them from simplest to most complex:
1. Flow track or pulley conveyors. They are made from formed or stamped steel, and the material is usually galvanized or powder coated steel. The flow track has rollers mounted to the frame, and sometimes there is an additional set of wheels mounted at 90 degrees that act as side guides. The pulleys can be plastic or galvanized steel. They are primarily used in horizontal format grow systems.
2. Gravity roller conveyors. Roller conveyors are simple, cost-effective, and can move product under its own weight if properly set up at the correct incline angle. They are often used with horizontal format systems that use pallets, containers, or totes.
3. Belt conveyors. Belt conveyors are often used with horizontal format grow systems. They have both food grade and non-food grade alternatives. If specified as food grade, both the belt material and the frame will have specific material requirements and will be easy to clean.
4. Motorized roller (MDR) conveyors. These conveyors have motors built into the conveyor rollers, so the conveyor drive system is completely protected from contamination. The conveyor length is divided into appropriate zones, each with one or more product pallets, and each with its own motor, sensors, and controller. The rollers are connected by O-rings or Poly-V ribbed belts. MDR systems provide farms with buffering capabilities to ensure smooth product movement in and out of the harvest room or operation.
5. Vertical Lifts. These are used to transport product from one level to another. They are primarily used in horizontal pallet systems, and a single lift can achieve vertical transfers of up to 40 feet.
6. Automated Storage and Retrieval Systems (ASRS). These highly complex material handling systems can traverse across the front of a row of racks or traverse along aisles between racks. Stacking cranes provide two-dimensional movement. Mechanisms mounted on the ASRS stacking crane carriage can place product in and out of the rack storage system.
7. Overhead Conveyors. This material handling system is often used in vertical format planting systems used in conjunction with vertical agricultural conveyors. Smaller systems may use a hand-pushed beam trolley system, while larger farms often use powered overhead conveyors, or even the most sophisticated types are powered and free conveyors.
