Avancon unveils ZPC belt conveyor designed to cut downtime in package handling

Avancon has introduced a new ZPC belt conveyor system for post offices and express delivery networks that need to move packages of many shapes and sizes. The company says the modular design can reduce belt-replacement downtime to just a few minutes and cut operating energy use by as much as 84%.

Why it matters: - Post offices and express carriers handle cardboard boxes, polybags, thick letters and irregular parcels every day. - Avancon’s new ZPC belt conveyor is designed to move those mixed package types without the flat-bottom requirement of its existing roller conveyor. - The system is built to reduce replacement downtime to a few minutes, which can help keep sorting and transport lines running. - Avancon says the design can also lower operating energy use by approximately 30% to 84%.

What happened: - Avancon developed a new ZPC belt conveyor system for package handling. - The company says the new system keeps the aluminum exterior design of its existing ZPC roller conveyor, while using a different internal structure. - The new conveyor zone is a short belt section sized to the longest item to be transported plus 25 millimeters. - The system is designed for pressure-free accumulation using the same controls, light barrier, control boxes and firmware used in the ZPC roller conveyor.

The details: - Each zone belt is a self-contained conveyor belt that is pre-tensioned and centered. - A redesigned profile lets operators open one side of the outer frame and replace a zone conveyor without removing the full system. - The replacement unit includes the permanently mounted axial-flux BLDC flat motors. - The zone belt sits inside the outer frame when the assembly is closed. - If a belt is damaged, the system can be restored by swapping in a new belt and reconnecting the motors. - The old belt can be repaired, tested and reused later in another zone. - The flat cables are pressed into ribs in the aluminum profiles so the cables stay parallel. - Control boxes with blades underneath can be pressed into place at any location. - The motors are the same axial-flux BLDC motors used in Avancon’s ZPC roller conveyors, but in a dual-synchronous configuration. - A central control cabinet and external cable routing are no longer required. - Cables, controllers and motors are built into each zone’s frame structure, and the firmware is preloaded. - ASi is used as the bus software, with gateway connectivity to higher-level PLCs, IT infrastructure and bus systems such as Profinet.

Between the lines: - The design shifts more intelligence and control into each conveyor zone, which should make installation and maintenance simpler. - The modular approach also suggests Avancon is targeting facilities where uptime matters more than a single long conveyor layout. - The claimed energy savings are broad, so actual results may vary by application and operating setup. - Avancon has patented the new design and the zone-belt replacement method in most industrialized countries worldwide.

What's next: - Avancon is positioning the system for use in post offices and express delivery operations that need flexible package handling. - The company’s patent protection could support broader commercial rollout in international markets. - The zone-belt replacement method is likely to be a key selling point for operators focused on fast maintenance and continuous operation.

The bottom line: - Avancon’s new ZPC belt conveyor is designed to handle mixed parcel types while cutting downtime, simplifying installation and reducing energy use.