Custom Towline Conveyor Systems for Industrial Manufacturing
We design, manufacture, and install light to heavy-duty towline conveyor systems that provide unmatched flexibility, precise process control, and long-term reliability for demanding industrial production environments with very little maintenance necessary.
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Towline Conveyors Designed for Your Process
As a leading towline conveyor manufacturer, we engineer our systems to handle complex manufacturing processes where flexibility, durability, and precise control are essential. Our fully custom, made-to-order systems allow individual carts to engage, disengage, and accumulate at defined process points, giving manufacturers the ability to adapt workflows, balance throughput, and support evolving production requirements without redesigning the entire line.
Benefits of Towline Conveyor Systems
A Patented Design Others Cannot Match
Our patented tow pin design enables cart engagement, disengagement, and accumulation anywhere along the line.
Built for Maximum Process Flexibility
Stop stations can be placed anywhere along the track, allowing processes to be positioned exactly where they are needed.
Automatic Accumulation With Fewer Failure Points
Multiple carts can automatically accumulate at a single stop station with reduced I/O and simpler controls.
Designed and Built in the USA
Our systems are engineered and manufactured at our facility in Louisville, Kentucky, with direct access to our engineering team.
Proven Lifecycle Performance
Towline systems typically operate 25 to 30 years, or 40 years or more with full preventative maintenance.
Modular, Made-to-Order System Design
Every towline system is custom designed using our modular track architecture to fit your facility, loads, and production process.
Controls for Any Environment
We offer air logic controls for explosion-proof environments and modern 24V PLC controls that integrate with robotics and automation.
In-Floor Towline Conveyor Systems
Our in-floor towline conveyor systems maximize usable floor space with a flush-to-floor design that supports heavy-duty operation while allowing people, equipment, and material handling traffic to move seamlessly.
Towline systems typically operate 25 to 30 years, or 40 years or more with full preventative maintenance.
Optional stiffeners allow forklift traffic to cross the track without interrupting production.
Integrated transfers connect multiple towline paths, greatly expanding layout flexibility.
Modular design allows in-floor towline systems to adapt as production needs change.
On-Floor Towline Conveyor Systems
Our on-floor towline conveyor systems provide a cost-effective solution for facilities where in-floor installation is not practical, while delivering the same heavy-duty performance and flexibility as our in-floor systems.
On-floor towlines support robotic and finishing applications with elevated track placement.
Available in both on-floor and in-floor configurations, allowing installations to be tailored to facility requirements and production goals.
On-floor systems retain the same flexibility, control, and durability as our in-floor towlines.
This configuration delivers proven towline performance in our most cost-effective package.
Cart Position Options for Your Process
Available for all tow line conveyors models
Side Tow Configuration
Side tow configurations are a great option for on-floor towline systems when flexibility is required to remove carts from the track or reposition them within the facility. This configuration is commonly used when only one side of the product needs to be accessed or when floor space is limited, making it well suited for finishing applications, robotic cells, and environments where space efficiency and process access are critical.
Center Tow Configuration
Center tow is by far our most popular cart mounting option, offering the greatest versatility across a wide range of applications. Especially when paired with an in-floor towline design, center tow configurations provide balanced pulling forces, support heavy to ultra-heavy loads, and enable the use of transfers and multiple caster options to accommodate complex layouts and demanding production requirements.
Frequently Asked Questions
What types of products and load weights can towline conveyor systems handle?
Towline conveyor systems are designed to handle a wide range of products and load weights, from moderate assemblies to heavy and ultra-heavy industrial components that require precise control and stability throughout the production process. These systems are especially well suited for applications where loads vary, product geometry is complex, or processes require frequent stopping, accumulation, or routing flexibility.
Towline systems use custom-engineered carts and dollies that are built specifically for the product being conveyed, allowing load capacity to be matched precisely to weight, size, and center-of-gravity requirements. Depending on the application, systems can be configured to move individual parts, large fabricated assemblies, or high-capacity carts carrying multiple components. Center tow configurations are commonly used for heavy and ultra-heavy loads, providing balanced pulling forces and consistent tracking, while side tow options support lighter loads or applications requiring cart removal. Because every system is custom designed, towline conveyors can be engineered to support demanding weight requirements without compromising flexibility or long-term reliability.
What makes RSI’s towline conveyor systems different from competitors’ designs?
RSI’s towline conveyor systems are differentiated by patented technology, made-to-order engineering, and a level of flexibility that competing systems cannot match. Rather than adapting standard designs, we engineer each towline system from the ground up to meet the exact requirements of the customer’s process, facility, and long-term production goals.
Our patented tow pin design allows carts to engage, disengage, and accumulate at virtually any point along the track, enabling near-infinite process location and automatic accumulation without added control complexity. This reduces I/O requirements, simplifies programming, and improves long-term reliability compared to conventional towline systems. Systems are manufactured in the United States at our facility in Louisville, Kentucky, ensuring consistent quality and direct collaboration with our engineering team. With modular track construction, advanced control options, and proven system lifecycles measured in decades, our towline conveyors are built as true workhorses of the industry, delivering durability, adaptability, and performance competitors struggle to replicate.
How do I decide between a side tow and center tow configuration?
The choice between a side tow and center tow configuration depends on your load requirements, layout constraints, and how carts need to interact with the rest of your production process. In most cases, center tow is the preferred option for heavy or complex applications, while side tow is selected for flexibility and space-sensitive layouts
Center tow configurations are by far the most common because they provide balanced pulling forces, superior tracking, and greater versatility across a wide range of applications. This setup is ideal for heavy to ultra-heavy loads, supports the use of transfers, and works well with multiple caster options, especially in in-floor towline systems where long-term stability and expandability are critical. Side tow configurations are typically used in above-floor systems when carts need to be easily taken on and off the track, when only one side of the product requires access, or when floor space is limited. Evaluating product weight, process access, future expansion, and layout flexibility early helps determine the best configuration for long-term performance.
How long do towline conveyor systems typically last?
Towline conveyor systems are built for long-term industrial use and typically remain in service for several decades when properly maintained. With minimal routine maintenance, many towline systems operate reliably for 25 to 30 years, and with a full preventative maintenance program, system lifecycles of 40 years or more are common.
This longevity is the result of heavy-duty construction, proven mechanical designs, and components engineered specifically for demanding production environments. Towline systems are designed to handle continuous operation, high loads, and frequent starts, stops, and accumulation without excessive wear. Modular track sections, robust carts, and serviceable components allow systems to be maintained, repaired, or upgraded over time rather than replaced. Because systems are custom engineered for the application rather than forced into a standard design, stress points are minimized and performance remains consistent over the long term. For many manufacturers, a towline conveyor system becomes a permanent part of the facility, supporting multiple generations of products and production changes over its lifespan.
Can towline conveyor systems integrate with robotic cells or automated processes?
Yes, towline conveyor systems are well suited for integration with robotic cells and automated manufacturing processes. They provide precise cart positioning, repeatable stopping accuracy, and flexible routing that automation and robotics depend on for consistent operation.
Towline systems can be configured to stop, accumulate, or release carts at exact process locations, making them ideal for robotic welding, painting, coating, assembly, inspection, and material handling cells. Advanced PLC control packages allow the conveyor to communicate seamlessly with robots, vision systems, and plant-wide controls, while air logic controls can be used in hazardous or explosion-prone environments. Both in-floor and above-floor towline configurations support automation, with above-floor systems often preferred for robotic cells where elevated track placement simplifies guarding and access. Because the system is custom engineered, integration points, timing, and control logic are designed around the automation rather than adapted afterward. The result is a coordinated, reliable system where conveyors and robotics operate as a single, integrated production solution.
Can RSI integrate a towline system into an existing production line or facility?
Yes, we regularly integrate towline conveyor systems into existing production lines and operating facilities without requiring a complete teardown or replacement of current equipment. Towline systems are especially well suited for retrofit projects because they can be engineered to work around existing layouts, processes, and space constraints.
During the design phase, we evaluate your current production flow, equipment interfaces, and facility conditions to determine the most effective integration approach. Systems can be configured as in-floor or above-floor installations depending on structural limitations, and transfers or connection points can be added to link new towline paths with existing conveyors, automation, or workstations. Control systems are designed to communicate with current PLCs, robotics, or plant-wide controls, allowing the towline system to function as a seamless extension of your operation. By designing the system specifically for your facility, we minimize disruption, reduce installation risk, and ensure the new towline conveyor enhances performance without compromising ongoing production.
Does RSI handle the design, installation, and startup of towline conveyor systems?
Yes, we handle the complete design, installation, and startup of towline conveyor systems, providing a true turnkey solution from concept through production-ready operation. Our team remains involved throughout the entire project lifecycle to ensure the system performs exactly as intended in your facility.
The process begins with in-house engineering, where we work directly with your team to define system layout, load requirements, controls, and integration points. Once the design is finalized, manufacturing is completed at our U.S. facility, followed by coordinated installation and on-site integration. Our installation teams understand the system because they are working from designs created internally, reducing handoffs and minimizing risk during execution. During startup, we test system operation, verify controls and process sequencing, and support commissioning to ensure carts, transfers, and automation interfaces perform reliably from day one. By managing design, installation, and startup under one roof, we deliver accountability, consistency, and a smoother path to full production.
Can towline conveyor systems be expanded or reconfigured over time?
Yes, towline conveyor systems are specifically designed to be expanded and reconfigured as production requirements change over time. Their modular construction and flexible routing make them well suited for facilities that expect growth, process changes, or evolving product lines.
Track sections, stop stations, and transfers can be added, relocated, or reconfigured to support new processes without requiring a complete system replacement. In-floor towline systems can be expanded by extending track runs or adding transfers that connect multiple lines, similar to a railroad-style layout, while on-floor systems allow for even faster layout changes when floor modification is not desired. Carts and dollies can also be redesigned or upgraded to accommodate new products, weights, or process requirements. Because systems are engineered as made-to-order solutions rather than fixed templates, expansion is planned into the original design whenever possible. This allows manufacturers to adapt workflows, increase capacity, or introduce automation while protecting the long-term value of the original investment.