The 24V Zero Line Pressure Powered Conveyor is designed for smooth, near-silent operation, offering a flexible and efficient drive solution suitable for diverse applications. Available with round belt or Poly V belt drive options, this system features brushless, gearless 24V DC motors positioned beneath the conveyor rollers to protect against impact loads. Its innovative design maximises efficiency, minimises wiring, and simplifies system maintenance, making it an ideal choice for modern material handling needs.
On an ordinary powered conveyor, when the front box stops the boxes behind it keep arriving and push into it. That is line pressure, and it is what scuffs labels, crushes corners and jams releases. Zero line pressure removes it by driving and controlling every zone independently: when a zone is occupied, the zone behind it stops, so product accumulates without ever touching. It is the difference between a queue and a pile-up.
The drive is 24V DC brushless gearless motors mounted underneath the rollers rather than out at the side. Underneath matters: it puts the motor out of the way of impact loads, which on a busy infeed is where drives usually die. Gearless means no gearbox, so no oil changes and one less wear item. Brushless 24V is also near-silent next to an AC or chain drive, which is a real consideration in a pick and pack hall where people work beside the line all day.
The whole range runs on two motors. The UD035 gives 12 to 35 W of output and is the standard choice; the UD060 gives 12 to 60 W where the load or speed demands it. Two motors covering every width and speed is a deliberate stocking decision as much as an engineering one, because it means a small spares shelf covers the entire line rather than a different motor for every section.
Zones are driven either by round belt or by Poly-V. Round belt suits standard duty and runs quieter. Poly-V carries more torque and is more efficient and more durable, so it is the answer for heavier loads or higher speeds. This is worth deciding at design rather than later, because it is tied to the duty the line will actually see rather than to the product on it.
The cabling is pre-wired and rated at 35 A, and a single power feed typically covers up to 20 zones using UD035 motors, with the exact count depending on load, speed and duty. That is the number that quietly decides installation cost: fewer power points means less containment, less cable, less electrical work and fewer things to commission. Plug connections finish the job, so on-site cable preparation is minimal and the usual crop of wiring faults largely disappears.
Each card carries six smart inputs and outputs, so photo-eyes and field devices connect without a separate wiring loom back to a panel. The useful part is that the cards are self-learning: replace one and it adopts the settings for its zone automatically, with no reprogramming. That turns a card failure from a call-out with a laptop into a part swap that maintenance can do on the spot.
Cartons, totes and trays are the normal traffic, and the load a zone will take depends on roller width, pitch and which motor is fitted, so it is sized per application rather than quoted as a single figure. The environment matters more than people expect: zero line pressure is for dry, non-washdown areas. Where the line gets washed, the answer is a different machine entirely, either modular belt conveyors or <a href="https://conveyors.ie/product/stainless-steel slat conveyors.
This is the real comparison and it is worth being straight about. Zero line pressure gives true zero pressure and per-zone control, and it runs quieter. Lineshaft conveyor gives low-pressure accumulation with far fewer drives and lower capital cost, which makes it the better buy on long, simple runs where product can tolerate a little contact. Pick zero pressure when the product is delicate, the mix is varied, or you need to route and sequence by zone. Pick lineshaft when the run is long, the product is robust and the budget is the constraint.
Typical use is pick and pack stations, conveyorised buffering, infeeds and outfeeds either side of labelling and machine vision, sequenced feeding to palletising, zone routing in FMCG and electronics, and interfaces to storage and retrieval systems. It integrates with PLC and HMI control, SCADA and MES, and takes merges, diverters and pop-up transfers where the layout needs them. Where a stretch of line only has to move product from A to B, gravity roller conveyors do it for a fraction of the cost, and most good layouts mix the two. LVP Automation specify, install and support these from Finglas, Dublin 11 as part of our wider automation services.
Ideal for mixed carton/tote flows that need true ZPA, gentle handling and quiet running. Perfect for e-commerce, order fulfilment, pharma/medical devices (dry areas) and kitting lines where stoppages must not cause product contact.
Photo-eyes per zone, accumulation logic, merges/diverters, pop-up transfers, barcode/RFID, vision and weight checks. PLC/HMI integration, VFD/zone control, SCADA/MES connectivity and safety circuits as required.
Pick/pack stations, conveyorised buffering, infeed/outfeed to labelling and vision, sequenced feeding to palletisers, zone routing in FMCG and electronics, and AS/RS interfaces.
Quick answers on loads, zones, motors, noise, maintenance and when to choose ZLP over other conveyor types.
Each zone is motorised and independently controlled, so items stop without touching, preventing scuffing and pressure damage.
Round belts suit standard duty and lower noise; Poly-V provides higher torque, efficiency and durability for heavier loads or higher speeds.
With pre-wired 35A cabling, a single feed typically powers up to ~20 zones using UD035 motors (exact count depends on load/speed/duty).
Great for cartons, totes and trays. Zone load depends on roller width/pitch and motor type (UD035 vs UD060); we size per application.
24V brushless, gearless drives are near-silent compared with AC/chain drives. Actual dB depends on product and speed.
Yes. Zone parameters are configurable, and self-learning control cards simplify swap-outs, with no reprogramming needed on replacement.
Routine cleaning and visual checks on belts/Poly-V, sensors and rollers. No gearbox oil changes; 24V motors are low-maintenance.
ZLP is for dry, non-washdown environments. Use stainless/modular belt systems for washdown applications.
ZLP delivers true zero-pressure and per-zone control with quieter operation; lineshaft offers low-pressure accumulation with fewer drives and lower capex for long, simple runs.
Usually a small set: UD035/UD060 motors, a few control cards, belts/Poly-V and sensors. Standardised components reduce inventory.
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