An Overhead Conveyor Line is a material handling system that moves products along a track suspended above the working floor. Trolleys run on an I-beam or enclosed track, pulled by a continuous chain, so parts can travel through workstations, paint booths, ovens and storage areas without taking up floor space.

That single sentence is the short answer. The rest of this guide explains how the system actually works, what it is made of, the main types, and how to judge whether an overhead conveyor is the right choice for your plant.

For a full overview of system configurations, see Overhead Conveyor Lines 

How does an overhead conveyor work?

Every overhead conveyor, regardless of type, follows the same basic loop:

A track defines the route. The track is suspended from the building structure - usually by hanger rods or brackets - and carries the load above the floor.

A continuous chain runs inside or on the track. The chain is the transport medium. It moves at a constant speed and is kept under tension by a take-up assembly.

Trolleys ride the track and carry the load. Each trolley is attached to the chain (directly, or through a pusher dog in power and free systems) and holds a load bar, hanger or fixture.

A drive unit pulls the chain. An electric motor and gearbox drive a sprocket that engages the chain, typically at a corner or at the longest straight section.

The route closes the loop. Parts pass through each station on the way around and return to the loading point.

Because the whole route is overhead, the floor below stays free. Operators, forklifts and other equipment can work underneath the moving line, and the conveyor can pass over machinery, aisles and storage areas that a floor-level system could not cross.

Key components of an overhead conveyor

A failure in any one of these components stops the line, which is why spare-part availability matters as much as the initial price.

Types of overhead conveyors

The main types differ in how the trolley is supported and whether carriers can move independently:

Manual overhead conveyor - the operator pushes the trolley. Lowest cost, no drive, used for short transfer and low-volume operations.

I-beam monorail overhead conveyor [/overhead-conveyor/i-beam-monorail/] - heavy trolleys run on the lower flange of a welded I-beam. The most robust option for heavy loads. Standard I-beam track heights are commonly 3", 4" and 6".

Enclosed track overhead conveyor [/overhead-conveyor/enclosed-track/] - the chain runs inside a closed steel or aluminium profile. Protects the chain from dust, paint and contaminants, runs quieter, and is the usual choice for finishing lines.

Power and free overhead conveyor [/overhead-conveyor/power-and-free/] - two tracks: a continuously moving power chain and a free track that carries the carriers. Carriers can stop, accumulate and move at different speeds independently - essential where stations have different cycle times.

Accumulating electric monorail - each carrier has its own drive, giving the highest routing flexibility at the highest cost.

Trolley conveyor [/conveyor-trolley/] - a general-purpose chain-and-trolley line for moving parts between processes.

Choosing between these types depends on load, throughput, route complexity and how much independent station control you need. For most finishing and assembly lines the practical shortlist is enclosed track, power and free, or a combination of both.

Where overhead conveyors are used

Paint and powder coating lines- the most common application. Parts travel through pre-treatment, dry-off, spray booth, cure oven and cooling in one continuous route.

Assembly - sub-assemblies move between workstations at a controlled pace.

Manufacturing and metal finishing - plating, phosphating and washing lines.

Warehousing and distribution - overhead transport and buffer storage.

Airport baggage handling - high-volume, long-distance transport of bags.

Food and automotive - where floor space is scarce and cleanliness matters.

Load capacity and speed

There is no single specification - capacity depends on the track profile, trolley, chain and drive. As general industry guidance:

Enclosed track systems typically handle roughly 10–500 lb (about 5–230 kg) per carrier, at speeds commonly quoted between 5 and 60 ft/min (about 1.5–18 m/min).

I-beam monorail systems carry substantially heavier loads by using heavier forged chain and larger trolleys, at lower speeds.

Power and free systems generally operate at moderate payloads but offer the greatest control over station timing.

Exact figures must be calculated for your load, route and duty cycle - not copied from a catalogue.

What to consider before buying

Load - weight, size and the number of hanging points per part.

Throughput - parts per hour, and the cycle time of the slowest station.

Building - headroom, column positions, sprinkler clearance and floor loading.

Route - number of horizontal and vertical curves, inclines and switches.

Environment - ambient dust, moisture, and whether the line passes through an oven.

Station control - does any station need to stop parts independently? If yes, you need power and free.

Maintenance - lubrication access, spare-part availability and service intervals.

Expansion - leave room for additional stations and drives.

Why choose Hangzhou Ocean Industry

An overhead conveyor is a system, not a catalogue item. The track, chain, trolleys and drive must be matched to each other and to your route - which is why it pays to buy from the manufacturer who builds the components.

Hangzhou Ocean Industry Co., Ltd. has been manufacturing Overhead Conveyor Lines and conveyor components in Hangzhou, China since 2005. We supply complete systems and the parts that keep them running:

Complete Overhead Conveyor Lines - enclosed track, I-beam monorail, power and free, and overhead chain configurations

Conveyor chain - enclosed track chain, forged rivetless chain and heavy-duty series

Track, trolleys, drive units, take-up assemblies, hangers and spreaders

OEM and custom engineering: track layout, load capacity, hanger design and oven-rated components specified per project

Spare parts held in stock for fast delivery

Working directly with the manufacturer means components are specified together - chain pitch, sprocket and trolley geometry match by design, wear parts remain available years later, and layout questions are answered by the people who build the parts.

Quality you can verify: ISO 9001 · ISO 14001 · ISO 45001 · CE · RoHS · SGS Verified

Request an overhead conveyor quote- tell us your load, route and throughput, and our engineers will tell you which type fits, and why.

FAQ

What is the difference between an overhead and a floor conveyor?

An overhead conveyor runs on a track suspended above the working floor, so it does not use floor space and can pass over aisles, machines and work areas. A floor conveyor runs at floor level, is easier to access for maintenance, but occupies and divides the floor.

How much weight can an overhead conveyor carry?

It depends on the track, trolley and chain. Enclosed track systems typically handle roughly 10–500 lb (5–230 kg) per carrier; I-beam monorail systems using forged chain carry much heavier loads. The correct figure must be calculated for your specific load and route.

What speed do overhead conveyors run at?

Industrial overhead conveyors commonly run between 5 and 60 ft/min (about 1.5–18 m/min). Finishing lines usually run at the lower end to allow adequate booth and oven dwell time.

Do overhead conveyors need lubrication?

Yes. The chain and trolley bearings require regular lubrication, and the interval depends on load, speed and temperature. Lines passing through ovens need high-temperature grease and more frequent inspection.

Can an overhead conveyor go around corners and up slopes?

Yes. Horizontal curves, vertical curves and inclines are standard track sections. The minimum radius and maximum incline depend on the chain type, load and speed, and must be checked at the design stage.

What is a power and free overhead conveyor?

It is a system with two tracks: a power track with a continuously moving chain, and a free track carrying the carriers. Carriers can be stopped, accumulated and released independently, which allows stations with different cycle times to work on the same line.

How long do overhead conveyors last?

With correct specification and maintenance, the track and drive typically last many years. Chains, trolley wheels and bearings are wear parts and are replaced on a schedule based on inspection - not on a fixed calendar.

Can overhead conveyors be customized?

Yes. Track layout, load capacity, hanger design, oven-rated components and control logic are all specified per project. Send your drawing or process route and the system can be engineered to match.

Who manufactures Overhead Conveyor Lines in China?

Hangzhou Ocean Industry Co., Ltd. has manufactured Overhead Conveyor Lines and components in Hangzhou, China since 2005, supplying enclosed track, I-beam monorail and power and free systems together with chain, track, trolleys, drive units and spare parts.

Request an overhead conveyor quote - have a drawing or a process route? Send it to us and our engineers will come back with a system recommendation and a quote.