24V Motorized Driven Roller (MDR) Conveyor System: Custom Automation Solution

Technology Overview

24 Volt Motorized Driven Roller (MDR) conveyor systems represent a modern, energy-efficient, and flexible approach to material handling automation. Unlike traditional conveyors powered by a single large motor, MDR systems use individual, low-voltage motors integrated into the rollers themselves. This creates independent, modular zones that can be controlled on demand, allowing products to accumulate without pressure and reducing energy consumption. The integration of specialized transfer modules, such as 90° pop-up units, extends their functionality, enabling complex routing and sortation within a compact footprint. These systems are ideal for carton, tote, and lightweight package handling in distribution centers, manufacturing, and packaging lines.

How It Works

Core Principles

The core principle is decentralized, zone-based propulsion. Each roller in an active zone contains a small, built-in 24V DC motor. These motors are activated only when a product is present in their zone and needs to be moved, creating an on-demand, energy-saving system. For directional changes, pop-up transfer units physically raise a set of powered rollers or belts to intersect the main flow, lifting the product and transferring it perpendicularly onto an adjoining conveyor lane.

Key Features & Capabilities

The foundation is the 24 Volt Motorized Driven Roller (MDR) technology, which provides a safe, low-voltage, and modular drive solution. Each system is a custom-designed conveyor system tailored to the specific spatial and throughput requirements of the customer's facility. A key functional component is the integrated 90° pop-up product transfer, which enables efficient right-angle diversion without the need for complex turntables or bulky transfer cars. The entire solution is engineered for optimal system layout and performance, with experts determining the ideal number and placement of MDR zones and transfer points.

Advantages & Benefits

A significant operational advantage is the ability to reduce operating costs through energy-efficient 24V operation, as motors run only when needed, unlike constantly running line-shaft or belt conveyors. Customers benefit from custom consultation and support from design through installation and aftermarket, ensuring the system is perfectly matched to their process. This end-to-end service helps maintain optimum performance of the automation line over its lifetime. The inherent nature of MDR technology provides a flexible and modular conveyor solution that can be more easily reconfigured or expanded than traditional systems.

Implementation Considerations

A primary consideration is that the system requires custom engineering and consultation for optimal design, including determining the correct number and location of MDR zones to balance cost, throughput, and accumulation needs. Professional installation is recommended to guarantee proper setup and operation, as correct alignment of zones, sensors, and transfer mechanisms is critical for reliable performance.

Use Cases & Applications

Ideal For

This system is ideal for medium-duty applications requiring flexible routing, accumulation, and sortation of boxes, totes, or polybags, such as in e-commerce fulfillment centers, parcel distribution hubs, and production kitting lines.

Conclusion

The custom 24V MDR conveyor system with integrated pop-up transfer from Thomas Conveyor & Equipment offers a sophisticated and efficient solution for modern material handling challenges. By combining the energy savings and flexibility of zone-based MDR technology with the precise routing capability of pop-up transfers, it provides a powerful tool for optimizing logistics workflows. The vendor's commitment to end-to-end custom engineering and support ensures that the system delivers on its promise of reduced operating costs and sustained high performance. For operations looking to automate carton and tote handling with intelligence and efficiency, this type of tailored MDR solution is a compelling choice.