Custom Overhead Conveyor Systems for Industrial Manufacturing
We design, manufacture, and install overhead conveyor systems that maximize floor space, support high-throughput production, and integrate seamlessly with finishing, assembly, and automated manufacturing environments.
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Overhead Conveyor Systems Designed for Your Process
As a leading overhead conveyor manufacturer, we engineer our systems to move products efficiently through manufacturing, assembly, and finishing operations while freeing up valuable floor space. Ideal for light to medium-weight products and high-throughput environments, these systems support complex process sequencing, tight layout constraints, and seamless integration with automated and manual operations. Each system is custom engineered to fit your facility, production flow, and long-term operational requirements.
Benefits of Overhead Conveyor Systems
Maximizes Usable Floor Space
Overhead conveyor systems keep products elevated, freeing up floor space for equipment, operators, and material handling.
Built for High-Volume Production
Designed for continuous operation, overhead systems support high-output manufacturing and finishing environments.
Flexible Layouts for Complex Facilities
Tight turns and adaptable routing allow overhead conveyors to fit space-constrained facilities and complex layouts.
Engineered for Finishing and Assembly Applications
Overhead systems integrate cleanly into finishing, washdown, and assembly processes for controlled product flow.
Patented Design for Reliable Operation
Our patented tow pin technology delivers precise control and proven towline performance in overhead applications.
Highline Overhead Conveyor Systems
Our Highline overhead conveyor systems provide an efficient overhead solution for manufacturing and finishing environments where space is limited, using tight turns and flexible routing to maintain smooth material flow without sacrificing process control.
This configuration allows tight turns where space is limited within complex facility layouts.
This system uses our patented tow pin technology to deliver unmatched process flexibility.
This design supports precise routing and adaptable workflows as production needs change.
Dripless Highline Overhead Conveyor Systems
Our Dripless Highline overhead conveyor systems are designed for high-end finishing, washdown, and blasting applications, using an enclosed, dripless design to protect the process area and ensure consistent finish quality.
This design keeps mechanical lubricants out of the finishing area during operation.
This configuration protects chain and stop station components in harsh environments.
This system minimizes debris buildup to improve reliability and finish quality.
Frequently Asked Questions
What types of products are best suited for overhead conveyor systems?
Overhead conveyor systems are best suited for products that benefit from floor space clearance, consistent movement, and controlled handling throughout production, finishing, or assembly processes. They are commonly used for parts that can be suspended or supported from above without compromising stability or access.
Overhead systems are ideal for light to medium-weight products, including fabricated components, frames, assemblies, and finished parts moving through paint, coating, curing, washdown, or inspection processes. Suspending products overhead allows equipment, operators, and material handling traffic to move freely below the conveyor path, improving overall plant efficiency. Overhead conveyors are also well suited for products that require continuous flow or repeated processing steps, as they maintain consistent spacing and orientation throughout the system. Because carts, hangers, and carriers are custom engineered, overhead systems can be adapted to product geometry, weight distribution, and process requirements. This flexibility makes overhead conveyors a strong choice for manufacturing environments focused on space optimization and process consistency.
How do overhead conveyor systems differ from towline conveyor systems?
Overhead conveyor systems differ from towline systems primarily in how products are supported, routed, and integrated into the production environment. Overhead systems suspend loads above the floor, while towline systems move carts along a track embedded in or mounted above the floor.
Towline systems are often selected for heavy or ultra-heavy products that require stable cart-based transport, precise accumulation, and frequent interaction with operators or equipment at floor level. Overhead systems, by contrast, are typically used when floor space is limited or when suspending the product improves access, cleanliness, or process flow. Overhead conveyors are commonly used in finishing, washdown, and blasting applications, where keeping mechanical components out of the process area is critical. Both systems offer flexible routing and integration with automation, but they serve different layout and handling priorities. Choosing between them depends on product weight, process requirements, facility constraints, and long-term production goals.
When is an overhead conveyor system the best choice for a facility?
An overhead conveyor system is the best choice when floor space is limited, product flow needs to be elevated, or production processes benefit from suspended handling. These systems are especially effective in facilities where clear floor access improves safety, efficiency, or automation.
Overhead conveyors are commonly selected for finishing lines, robotic cells, and washdown environments where keeping the floor clear simplifies guarding, access, and material handling. They are also ideal when concrete modification is not practical or when existing facilities must be retrofitted with minimal disruption. By routing material above work areas, overhead systems allow equipment, forklifts, and personnel to operate freely below the conveyor path. This can significantly improve layout efficiency without expanding the facility footprint. Because overhead conveyors are custom engineered, they can navigate tight turns, elevation changes, and complex routing to fit challenging layouts. For facilities prioritizing space optimization and process continuity, overhead conveyors often provide the most effective solution.
What is the difference between Highline and Dripless Highline conveyor systems?
The primary difference between Highline and Dripless Highline conveyor systems lies in how they manage lubrication and environmental protection within finishing and processing areas. Both are overhead systems, but they are designed for different operating conditions.
Highline conveyors are a traditional overhead solution that provides flexible routing, tight turns, and reliable material flow in space-constrained environments. They use RSI’s patented tow pin design to deliver precise process control and flexibility across a wide range of applications. Dripless Highline systems are engineered specifically for high-end finishing, washdown, and blasting environments. Their enclosed, C-shaped carrier design prevents mechanical lubricants from entering the finishing area, helping maintain surface quality and reduce contamination. The enclosed chain also protects internal components from debris and media buildup. While both systems offer durability and flexibility, Dripless Highline systems are selected when finish quality, cleanliness, and environmental protection are critical.
Can overhead conveyor systems integrate with robotic cells or automation?
Yes, overhead conveyor systems integrate effectively with robotic cells and automated manufacturing processes when precise positioning and repeatable movement are required. They are commonly used to support automated finishing, assembly, and inspection operations.
Overhead systems can be engineered to stop, index, or accumulate products at exact process locations, allowing robots to interact with parts consistently and accurately. Custom carriers, hangers, and fixtures ensure products are presented in the correct orientation for robotic operations. Control systems are designed to communicate with robots, PLCs, and plant-wide automation, enabling coordinated movement and timing. Overhead conveyors are especially effective in robotic environments because they keep mechanical components out of the work zone, simplifying guarding and access. Because the system is designed around the automation rather than adapted afterward, integration points, controls, and sequencing are optimized from the start, resulting in reliable, repeatable performanc
Can overhead conveyors be integrated into existing production lines?
Yes, overhead conveyor systems can be integrated into existing production lines and facilities with minimal disruption when properly engineered. They are well suited for retrofit projects where expanding or reconfiguring material flow is required.
During the design phase, existing layouts, equipment interfaces, and facility constraints are evaluated to ensure the overhead system complements current operations. Routing can be designed to avoid structural obstacles, equipment, and work areas while connecting seamlessly to existing conveyors, workstations, or automation. Overhead systems are particularly effective in retrofits because they do not require in-floor excavation or major concrete work. Controls can be integrated with existing PLCs and automation platforms to ensure coordinated operation. By designing the system specifically for the facility, overhead conveyors can enhance production flow, increase capacity, and improve efficiency without requiring a complete reconfiguration of the plant.
How customizable are overhead conveyor layouts and routing?
Overhead conveyor layouts are highly customizable and can be engineered to fit complex facility layouts, process requirements, and future expansion plans. Routing flexibility is one of the primary advantages of overhead systems.
Custom track designs allow overhead conveyors to navigate tight turns, elevation changes, and long or compact runs within a single system. Routing can be optimized to support multiple process stages, parallel lines, or continuous loops depending on production needs. Because systems are modular, sections can be added, relocated, or reconfigured as processes evolve. Custom carriers and hangers are also designed to match product geometry and handling requirements. This level of customization allows overhead conveyors to adapt to challenging layouts while maintaining efficient material flow. By engineering the system around your facility rather than forcing standard layouts, overhead conveyors provide long-term flexibility and scalability.
Does RSI handle the design, installation, and startup of overhead conveyor systems?
Yes, we handle the complete design, installation, and startup of overhead conveyor systems, delivering a turnkey solution from concept through production-ready operation. Our team remains involved throughout the entire project lifecycle.
The process begins with in-house engineering, where system layout, load requirements, routing, and integration points are defined in collaboration with your team. Manufacturing is completed to match the approved design, followed by coordinated installation and on-site integration. Because installation teams work from internally developed designs, execution is efficient and issues are minimized. During startup, systems are tested, controls are verified, and integration with automation or existing equipment is validated. This end-to-end approach ensures accountability, consistency, and reliable performance from day one, allowing the system to enter production smoothly and confidently.