The drive behind a pallet conveyor rarely gets much attention at the design stage. The layout, the footprint, the throughput numbers get the focus. But the drive is what decides the power bill, the noise on the floor, and how much of the line sits idle waiting on the next pallet, for as long as that conveyor runs.
For pallet handling, the choice comes down to two drive types.
1. AC three phase gearmotor drive, the long-standing standard for heavy conveying
2. DC motor driven roller, or MDR, running at 24 or 48 volts with zoned control
Getting this choice right at the start avoids a rebuild later. Here is how to think it through.
Start with the pallets themselves, not the conveyor. A site running heavy, irregular, or well used pallets (the kind with broken boards, protruding nails, or the odd forklift dent), needs a drive that will not stall or hesitate over the damage. AC drive, with its positive chain engagement, keeps moving regardless. It also holds the highest load capacity of the two, into the thousands of kilograms per unit.
A site running sound, regular pallets has more room to move. DC and MDR handle these loads well, up to about 1,225 kg and 70 inches wide, and open options that AC cannot easily match on the next two questions.
Extreme heat, cold, or heavy washdown favour AC drive, which is built to handle harsh conditions with the right build. DC and MDR variants exist for washdown, IP66 and IP69K rated, and even freezer environments, but they have limits in ovens and extreme heat that AC does not.
Noise matters here too. AC drive is louder, chains and sprockets working continuously. MDR runs at about 70 dB or less, a real consideration for sites where noise on the floor is a genuine operational concern, not just a comfort issue.
This is where the two drive types diverge most. AC runs continuously whether a pallet is present or not. MDR zones only run on demand, typically active 10 to 50 percent of the time.
PulseRoller, the exclusive New Zealand MDR line MCL distributes, publish savings of up to about 60 percent against AC as a result.
Upfront, AC tends to cost less for heavy, simple transport. MDR costs more per zone at installation, but the running cost and faster return on energy and accumulation can close that gap over the life of the conveyor.
--> Download the PulseRoller catalogue here.
If a line needs pallets to queue and release cleanly, zone by zone, this is where MDR earns its place. PulseRoller with ConveyLinx control gives native, precise zero pressure accumulation per zone. AC can achieve accumulation too, through zone motors, but the stop response is slower, about 1 to 3 seconds, which matters more as line speed and pallet frequency increase.
Installation reflects the same divide. AC needs heavier electrical work and more conduit for a central motor. MDR is plug and play at 24 or 48 volts, with less wiring and lower voltage safety considerations on site.
| Factor | AC three phase gearmotor | DC, 24 to 48V MDR (PulseRoller) |
|
Load capacity |
Highest. 1,000 to 1,500 plus kg, and up to several thousand kg per unit. |
Strong but bounded. Pallet rollers to about 1,225 kg and 70 inches wide. |
|
Heavy or irregular pallets |
Best. Positive chain drive tolerates broken boards, nails, plastic and foam pallets, and forklift impact. |
Good for sound, regular pallets. Less suited to very heavy or irregular loads. |
|
Energy use |
Runs continuously whether loaded or not.
|
Runs on demand. Zones run 10 to 50 percent of the time. PulseRoller publish up to about 60 percent saving against AC |
|
Zoned accumulation |
Possible via zone motors. Slower stop response, about 1 to 3 seconds. |
Native, precise zero pressure accumulation per zone. |
|
Noise and environment |
Louder, chains and sprockets. Robust in extreme heat, cold and washdown with the right build. |
Quieter, about 70 dB or less. IP54, IP66 and IP69K and freezer variants exist, but limits in ovens and extreme heat.
|
|
Install and wiring |
Heavier electrical, central motor, more conduit. |
Plug and play, 24 or 48V, modular, less wiring, lower voltage safety.
|
|
Serviceability |
Familiar mechanical parts. Chain lubrication is critical, a dry chain runs about three times the wear. |
Sealed, low maintenance rollers. Swap individual rollers. Depends on spares and controls. |
|
Cost posture |
Lower upfront for heavy simple transport. Higher running cost. |
Higher upfront per zone. Lower running cost, faster return on energy and accumulation. |
AC is the right choice for heavy and irregular pallets, harsh environments, and simple high load transport. DC and MDR fit lighter pallets, accumulation heavy layouts, quieter and safer floors, and energy conscious sites.
MCL builds AC drive systems in house and holds the exclusive New Zealand distribution of PulseRoller MDR technology, so the drive type gets matched to the job rather than to what a single supplier happens to offer. Most competitors in this market can only supply one or the other.
If you are specifying a pallet line and are weighing up AC drive against DC and MDR, MCL's design office can work through load, environment, and accumulation needs before anything is quoted