24VDC MDR Conveyor Systems

In conveyor systems, MDR stands for Motor-Driven Roller.

An MDR conveyor uses individual rollers with built-in motors to move products along the line. Instead of one large motor driving a whole section with belts or chains, each motorized roller (or a group of them) powers its own zone.

Key points:

• Energy efficient – rollers only run when needed.

• Modular – easier to scale or reconfigure since zones are independent.

• Low maintenance – fewer moving parts compared to chain- or belt-driven conveyors.

• Safe and quiet – less risk of injury and generally quieter operation.

They’re widely used in distribution centers, e-commerce warehouses, and manufacturing lines where flexibility and control are important.

A 24VDC MDR conveyor system uses low-voltage, direct-current motors to power conveyor rollers or zones. This provides greater energy efficiency, flexibility, and safety compared to traditional 480 VAC conveyor systems.

They use zone control, meaning each conveyor motor only runs when a product is present in that section. This reduces unnecessary energy use by up to 50%.

Yes. Since they operate at low voltage (24VDC), they present fewer electrical hazards while still offering strong performance for material handling.

Yes. While best suited for cartons, totes, and packaged goods, modern 24VDC conveyors can handle heavy-duty applications depending on motor size and design.

24VDC MDRs are designed to be safe around people, while ensuring the system as a whole is highly capable. Relatively low per-roller torque, distributed across many rollers, and aided by low rolling resistance is what makes 24VDC MDR conveyors both hand-safe and powerful enough to move thousands of pounds.

Absolutely. Facility Functions specializes in retrofitting older conveyor lines with 24VDC motors and controls to improve efficiency without replacing the entire system. This means that we can retrofit either parts or entire existing systems.

They are widely used in distribution, e-commerce, manufacturing, food & beverage, and pharmaceutical industries due to their flexibility and reliability.

Zero Pressure Accumulation (ZPA) is a conveyor control logic that allows products to be held or buffered on a conveyor line without touching each other. In a traditional conveyor, if the front item stops, the items behind it continue to be pushed forward by the motor, creating "back pressure" (the force of items crushing into one another). In a ZPA system, the conveyor is divided into "zones" that act independently to prevent this.

How ZPA Works

The system uses a combination of sensors and motorized rollers to manage traffic:

1. Zoning: The conveyor is divided into segments (zones), typically slightly longer than the longest product.

2. Sensing: Each zone has a photo-eye sensor. When a sensor detects a product, it "claims" that zone.

3. Communication: The zone communicates with the zone directly in front of it. - If the zone in front is occupied, the motor in the current zone stops immediately. - If the zone in front is clear, the motor runs to move the product forward.