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FAQ overhead conveyor technology2026-04-02T15:22:52+02:00
FAQ overhead conveyor technology

FAQ

Overhead conveyor technology

Basics & Technology

Which overhead conveyor systems does SCHÖNENBERGER offer?2026-04-02T10:43:52+02:00

SCHÖNENBERGER Systems offers four main systems that can be used individually or in combination, depending on requirements:

ILS 2100 sorting system – The modular flagship for sequencing and automated transport with intelligent mini trolleys and gyroscope-based sorting. Ideal for just-in-sequence deliveries in demanding e-commerce logistics.

ILS pocket sorter – high-speed sorting with up to 7,200 parts per hour. Combines hanging garments and flat goods sorting for efficient multi-channel e-commerce processes.

Omniflo Trolley System – Flexible multi-directionality with center-suspended design. Trolleys move in all directions across different levels without system breaks. Linkable trolleys enable fast batch picking.

CPC trolley-less systems – maintenance-free efficiency without conventional trolleys. Pressure-free transportation on inclines and in curves with minimum energy consumption.

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Was bedeutet ASRS-Integration und welche Vorteile bietet sie?2026-04-08T10:27:18+02:00

ASRS stands for Automated Storage and Retrieval Systems. The integration of overhead conveyor technology with ASRS technology completely revolutionizes textile logistics and automotive applications.

Advantages of ASRS integration:

  • 50% space saving thanks to intelligent vertical space utilization
  • Dynamic storage with optimized order picking at height
  • Automatic lift systems for fast goods movements between levels
  • Process reliability with seamless material flow control
  • Scalability for growing requirements without floor plan changes

All SCHÖNENBERGER overhead conveyor systems are designed for seamless ASRS integration and enable high-bay warehouse connections up to 20m high.

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What is overhead conveyor technology?2026-04-02T10:51:21+02:00

Overhead conveyor technology, also known as overhead conveyors, moves goods along a rail-guided system under the ceiling of warehouses or production facilities. In contrast to floor-bound conveyor systems, overhead conveyor technology uses the third dimension and thus enables efficient intralogistics material transport with optimum space utilization.

SCHÖNENBERGER Systems has been planning, developing and installing customized overhead conveyor solutions for customers worldwide for over 45 years. Our systems combine proven mechanics with state-of-the-art control technology and RFID integration.

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How does RFID tracking work in overhead conveyor systems?2026-04-02T10:44:10+02:00

Yes, all SCHÖNENBERGER overhead conveyor systems can be equipped with RFID technology (Radio Frequency Identification) and barcode systems. This tracking technology forms the digital backbone of modern intralogistics.

What RFID integration makes possible:

  • Real-time tracking of every single item in the system
  • Seamless traceability from goods receipt to dispatch
  • Automatic plausibility checks to minimize picking errors
  • KPI optimization through detailed evaluations
  • WMS/ERP integration with seamless connection to existing IT infrastructure
  • Quality assurance with automatic documentation for compliance

RFID technology is particularly valuable for demanding e-commerce operations where speed and accuracy are equally critical to success.

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Advantages & Performance

What throughput capacity do SCHÖNENBERGER overhead conveyor systems achieve?2026-04-02T11:05:46+02:00

The throughput performance varies depending on the system and configuration:

ILS pocket sorter:

  • Up to 7,200 parts per hour at maximum capacity
  • Combined hanging garment and flat goods sorting
  • Automatic forwarding to shipping buffers

ILS 2100 sorting system:

  • High-precision sequencing for just-in-sequence deliveries
  • Individual order production in batch size 1
  • Variable speed depending on requirements

Omniflo system:

  • Optimized for larger quantities and weights
  • Batch picking with linkable trolleys
  • Flexible speed adjustment

CPC Trolleyless systems:

  • Energy-efficient promotion
  • Continuous material flow without interruption
  • Ideal for buffer sections and batch delivery

All systems achieve 99% uptime thanks to preventive maintenance concepts and redundant design.

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How energy-efficient are overhead conveyor systems?2026-04-02T10:41:20+02:00

Modern overhead conveyor technology from SCHÖNENBERGER is designed for maximum energy efficiency:

Energy-saving concepts:

  • Frequency-controlled drives adapt power to actual demand
  • Recuperative braking systems feed back energy on downhill gradients
  • CPC Trolleyless systems with minimal energy consumption due to reduced rolling resistance
  • Intelligent controls avoid idle operation
  • Power & Free technology enables stowage without energy loss

Comparison with floor conveyors: Overhead conveyors typically require 30-40% less energy than comparable floor conveyors, as:

  • Less moving mass (no heavy conveyor belts)
  • Optimized routing with use of gravity
  • No friction losses on floor surfaces

Amortization through energy savings typically takes place within 3-5 years.

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What are the advantages of overhead conveyors compared to floor-bound conveyor systems?2026-04-02T10:52:57+02:00

Overhead conveyor technology offers decisive advantages that make the difference in demanding B2B environments:

Space optimization:

  • Use of vertical space above work areas and transport routes
  • Free floor space for value-adding activities
  • Up to 50% space saving thanks to ASRS integration
  • Clear, clean production and storage areas

Product protection:

  • Hanging storage prevents creasing of textiles
  • Protection against damage and soil contamination
  • Gentle transportation of sensitive components
  • Dust-free conveying in clean room environments

Process efficiency:

  • Automatic delivery at the right time in the right order
  • No search and travel times for employees
  • Throughput of up to 7,200 parts/hour with ILS pocket sorter
  • 99% system availability thanks to redundant design

Flexibility:

  • Combination of different systems (ILS, Omniflo, CPC)
  • Manual and automated sections in the same system
  • Expandable at any time without production downtime
  • Adaptable to changing requirements

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Applications & Industries

In which industries is overhead conveyor technology used?2026-04-02T10:52:23+02:00

SCHÖNENBERGER overhead conveyor systems have proven themselves in a wide range of B2B applications:

Textile and clothing logistics:

  • Garment-on-hanger (GOH) for fashion retailers
  • Textile service providers and laundries
  • E-commerce fulfillment for fashion
  • Size run completion for retail delivery
  • Returns processing with quality control

Automotive & Suppliers:

  • Just-in-sequence supply of production lines (e.g. Faurecia)
  • Seat covers, interior trim, bumpers
  • Component sequencing with many variants
  • Buffer storage for production fluctuations

E-commerce & omnichannel:

  • Multi-channel fulfillment
  • Same-day delivery thanks to fast throughput times
  • Flexible order batching by shipping method
  • Integrated packaging optimization

Industrial production:

  • Garment production
  • Mattress production and logistics
  • Furniture production
  • Electronics industry

Reference customers: Digel AG, bugatti Retail GmbH, Faurecia AG, Schera GmbH

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What can be transported with overhead conveyors?2026-04-02T10:50:37+02:00

SCHÖNENBERGER overhead conveyor technology transports a wide variety of goods of different sizes and weight classes:

Hanging goods:

  • Garments on hangers (GOH – Garment on Hanger)
  • Jackets, coats, suits, shirts, dresses
  • Curtains, drapes, home textiles
  • Automotive components (seat covers, trims)

Horizontal goods (with special load carriers):

  • Folded textiles
  • Flat goods, parcels, cartons
  • Mattresses and mattress covers
  • Furniture parts and components
  • Electronic assemblies

Combined transportation: The ILS pocket sorter allows hanging and flat goods to be transported and sorted together in one system – ideal for multi-channel e-commerce.

Weight capacity:

  • Lightweight textiles from 100g
  • Standard load up to 25kg per beam
  • Heavy load up to 80 kg with special trolleys
  • Automotive parts weighing up to several kilograms

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Can overhead conveyor technology also transport horizontal goods?2026-04-02T10:45:56+02:00

Yes, thanks to specially developed load carriers and brackets, even flat-packed goods can be transported with overhead conveyor systems without any problems. This is a decisive advantage over pure GOH systems.

Advantages of hanging transportation of flat goods:

  • Protection against soil contamination
  • No damage due to stacking on top of each other
  • Direct access without rearranging
  • Space-saving vertical storage
  • Can be combined with hanging goods in the same system

Typical applications:

  • Folded shirts and shirts in e-commerce
  • Packaged textiles and accessories
  • Flat goods in textile logistics
  • Automotive small parts in bags
  • Spare parts and accessories

The ILS pocket sorter is specially designed for this combination and sorts up to 7,200 mixed parts per hour.

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Planning & Implementation

Are load carriers customized?2026-04-02T10:46:21+02:00

Yes, in addition to proven standard components, SCHÖNENBERGER develops product-specific and customized load carriers for every project. Tailor-made solutions guarantee optimum performance.

Standard load carrier:

  • Hanger holders of various sizes
  • Universal trolleys for various goods
  • Pocket systems for flat goods
  • Heavy-duty fixtures

Customized developments:

  • Automotive components (seat covers, trims)
  • Mattresses and upholstery
  • Bulky industrial parts
  • Sensitive electronics
  • Multiple pick-ups for batch picking
  • Combination carriers for different types of goods

development process:

  1. Analysis of the transported goods (size, weight, properties)
  2. Concept development with 3D simulation
  3. Prototype construction and test runs
  4. Optimization and series release
  5. Documentation and spare parts concept

Customized load carriers are a key success factor for optimum material flow.

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Can an existing hall be retrofitted with overhead conveyor technology?2026-04-02T10:45:28+02:00

Yes, existing warehouses and production halls can easily be retrofitted with overhead conveyor technology from SCHÖNENBERGER. One of the major advantages of overhead conveyor technology is that it can be retrofitted.

Advantages of retrofitting:

  • No production downtime due to staged installation
  • Use of existing ceiling structures in most cases
  • Minimal intervention in existing processes
  • Rapid amortization due to immediate increase in efficiency

Technical requirements:

  • Sufficient ceiling load-bearing capacity (structural analysis required)
  • Minimum ceiling height approx. 3.5 m (depending on the system)
  • Accessibility for installation and maintenance
  • Electrical infrastructure

Expandability: All SCHÖNENBERGER systems have a modular design and can be expanded at any time:

  • Additional conveyor lines
  • Integration of further workstations
  • Connection of new storage areas
  • Capacity expansions without system conversion

Even combinations of different systems (e.g. Omniflo + ILS 2100) are possible without any problems.

Internal links:

SCHÖNENBERGER Systems Garment Production Retrofit
Schoenenberger-Systems Omniflo LTA Trolley

Can manual and automated sections be combined?2026-04-02T10:45:21+02:00

Yes, SCHÖNENBERGER overhead conveyors enable the seamless integration of manual and automated sections in the same system. This hybrid solution offers maximum flexibility.

Typical combinations:

  • Omniflo (manual) for flexible batch composition
  • CPC/FLEX (automated) for buffer sections and transports
  • ILS 2100 (automated) for sequencing and sorting
  • Manual workstations on automated main lines

Advantages of the hybrid solution:

  • Investment as required – gradually expanding automation
  • Flexible adaptation to different process steps
  • Optimal work-life balance between man and machine
  • Buffering between automated and manual areas

Application example: Goods receipt manual → automatic conveying to warehouse → ASRS automatic → automatic conveying to picking → manual picking → automatic conveying to dispatch

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Are inclines, declines and floor changes possible?2026-04-02T10:45:06+02:00

Yes, overhead conveyors from SCHÖNENBERGER can negotiate inclines, declines and even floor changes with ease. The three-dimensional routing is a key advantage of overhead conveyor technology.

Possible height changes:

  • Inclines: Depending on the system, up to 45° possible
  • Slope: Controlled lowering with braking devices
  • Vertical conveyor: Vertical transport between floors
  • Inclined conveyors: Smooth height transitions
  • Spiral conveyor: Space-saving height overcoming

Omniflo floor connection: The Omniflo system offers special components for floor changes:

  • Vertical conveying over several floors
  • No system breaks when changing height
  • Movement in all directions, even across levels
  • Seamless integration into building structures

Technical adjustments:

  • Inclination angle and speeds are optimally adjusted to the transported goods
  • Safety devices prevent rollback
  • Energy recovery on downhill gradients

This flexibility enables optimum use of space and direct transport routes – even in complex building structures.

Internal links:

SCHÖNENBERGER Systems Omniflo Floor Crossing

Maintenance & Service

What services does SCHÖNENBERGER offer?2026-04-02T10:38:51+02:00

SCHÖNENBERGER offers comprehensive services from a single source – from initial planning to long-term support:

Planning phase:

  • Feasibility analysis and determination of potential
  • 3D layout planning with visualization
  • ROI calculation and profitability analysis
  • Support with integration into existing IT systems (WMS, ERP)

Project phase:

  • Professional project management
  • Installation by experienced assembly teams
  • Commissioning and system optimization
  • CE conformity and acceptance

operating phase:

  • Training for your employees and maintenance technicians
  • Maintenance packages with preventive maintenance
  • Hotline support
  • Remote diagnostics and maintenance
  • Spare parts availability
  • Modernization and expansions

Long-term partnership:

  • Continuous process optimization
  • Technology updates
  • Capacity expansions
  • Lifecycle management
What happens in the event of a system failure?2026-04-02T10:38:12+02:00

System failures are extremely rare at SCHÖNENBERGER overhead conveyor technology, but comprehensive concepts are in place for emergencies:

Preventive measures:

  • Redundant design of critical components
  • Buffer zones enable partial operation in the event of faults
  • Automatic fault diagnosis detects problems at an early stage
  • Preventive maintenance proactively prevents failures

In the event of a fault:

  • Hotline for individual support
  • Remote diagnostics identify problems in minutes
  • Fast on-site service if required
  • Spare parts in stock for critical components
  • Manual emergency operation modes for bridging
How maintenance-intensive is overhead conveyor technology?2026-04-02T10:44:39+02:00

The maintenance requirements for overhead conveyor technology from SCHÖNENBERGER are very low – significantly lower than for floor-bound conveyor systems.

Typical scope of maintenance:

  • Regular inspections: Visual inspection every 3-6 months
  • Lubrication work: Automatic central lubrication reduces effort
  • Wear parts: Replacement only if necessary (rollers, chains)
  • Electrical components: Check once a year
  • Software updates: remote maintenance without system downtime

Low-maintenance construction:

  • CPC Trolleyless systems with minimal moving parts
  • Self-lubricating bearings and rollers
  • Robust design for continuous operation
  • Dust-protected drives

SCHÖNENBERGER maintenance package:

  • Preventive maintenance prevents unplanned downtime
  • Service hotline for emergencies
  • Remote diagnostics via the Internet
  • Spare parts availability guaranteed
  • Training for your maintenance technicians

Typical availability: 99% uptime with regular maintenance

Many customers report that SCHÖNENBERGER systems “have never let them down” (Andreas Broch, Digel AG).

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Profitability & ROI

How quickly does an investment in overhead conveyor technology pay for itself?2026-04-02T10:36:21+02:00

The amortization period depends on various factors, but is typically between 2-5 years:

Savings potential:

  • Personnel costs: 30-50% reduction due to elimination of search and transport times
  • Space costs: 50% space saving through vertical space utilization
  • Energy costs: 30-40% lower consumption vs. floor conveyors
  • Error costs: minimization through RFID tracking and automation
  • Storage costs: Optimized turnover rate

Increase in productivity:

  • Throughput up to 7,200 parts/hour (ILS pocket sorter)
  • 99% system availability
  • Significantly higher productivity per square meter
  • Reduction of non-value-adding activities

ROI calculation example: For a medium-sized textile logistics company with 5,000m² of warehouse space:

  • Investment: approx. 800,000 EUR
  • Annual savings: approx. EUR 250,000
  • Amortization: approx. 3.2 years
  • Useful life: 15-20 years

Non-monetary benefits:

  • Improved working conditions for employees
  • Greater delivery reliability and customer satisfaction
  • Competitive advantages through faster processes
  • Scalability for future growth

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What funding options are available for overhead conveyor technology?2026-04-02T10:28:27+02:00

Investments in intralogistics and automation can often be subsidized:

Possible funding programs (Germany):

  • KfW Energy Efficiency Program: low-interest loans for energy-efficient systems
  • Federal funding for energy and resource efficiency: grants of up to 40%
  • Regional funding programs: State-specific investment promotion
  • EU funding: For innovative automation projects
  • Digitization promotion: For IT integration and Industry 4.0

Prerequisites:

  • Energy efficiency certificate
  • CO2 savings
  • Degree of innovation
  • Workplace effects

SCHÖNENBERGER support:

  • Creation of required documentation
  • Energy efficiency certificates
  • Support during the application process

We recommend checking funding opportunities as early as the planning phase.

Technical specifications

What is the minimum ceiling height required?2026-04-02T10:25:57+02:00

The required ceiling height depends on the selected system and the application:

Minimum heights:

  • Omniflo system: From 3.5m ceiling height
  • ILS 2100: From 3.8m for standard applications
  • ILS pocket sorter: Recommended from 4.0m
  • CPC systems: Possible from 3.2m

Optimum heights for ASRS integration:

  • 6-12m: Standard high-bay warehouse
  • 12-20m: High-performance ASRS systems
  • Over 20m: special solutions possible

To be considered:

  • Clearance height under conveyor section (min. 2.2 m)
  • Maintenance access above
  • Height of the transported goods
  • Workstation ergonomics

Solutions for low ceilings:

  • Floor mounting with gantry constructions
  • Partial subsidence in secondary areas
  • Optimized carrier geometry

SCHÖNENBERGER plans individually for your room situation and finds solutions even for challenging conditions.

How is it integrated into existing IT systems?2026-04-02T10:24:42+02:00

SCHÖNENBERGER overhead conveyor systems can be seamlessly integrated into existing IT infrastructures:

Standard interfaces:

  • WMS (Warehouse Management System): Bidirectional communication
  • ERP systems: SAP, Microsoft Dynamics, individual systems
  • MES (Manufacturing Execution System): For production control
  • SCADA: Supervisory Control for monitoring
  • OPC UA: Standardized Industry 4.0 communication

Data transmission:

  • Real-time tracking via RFID/barcode
  • Order data and control commands
  • Status messages and alarms
  • Performance KPIs and analytics
  • Remote monitoring

The integration is carried out by SCHÖNENBERGER IT specialists together with your IT team.

What weights can be transported?2026-04-02T10:55:11+02:00

The weight capacity varies depending on the system and enables the transportation of everything from light textiles to heavy industrial parts:

Omniflo Trolley System:

  • Standard: 15-25 kg per trolley
  • Heavy duty: Up to 80 kg with reinforced components
  • Multiple trolleys: Coupled for even higher loads

ILS 2100:

  • Standard carrier: 5-15 kg
  • Optimized for individual parts and sequencing
  • Precise weight distribution

ILS pocket sorter:

  • Per bag: 3-8 kg
  • For light to medium-weight goods
  • Combination of hanging and lying goods

CPC Trolleyless systems:

  • Continuous load depending on version
  • Ideal for evenly distributed loads
  • Particularly energy efficient

Typical applications by weight:

  • 100g – 2kg: textiles, shirts, light clothing
  • 2-10kg: jackets, coats, packaged goods
  • 10-25kg: Heavy coats, automotive covers, mattresses
  • 25-80kg: industrial components, furniture parts, heavy goods

SCHÖNENBERGER develops customized solutions for special requirements.

Schönenberger systems in automotive production (seat covers)

Schönenberger systems in automotive production (seat covers)

Pouch sorter from SCHÖNENBERGER Systems for maximum variety when transporting goods

SCHÖNENBERGER Systems Pouch Sorters for maximum flexibility when transporting goods

Special questions

Is there a maximum track length for overhead conveyor systems?2026-04-02T13:17:58+02:00

No, theoretically there is no maximum track length. SCHÖNENBERGER plans and implements systems from a few meters to several kilometers in total length.

Realized system sizes:

  • Small: 50-200m (individual production areas)
  • Medium: 200-1,000m (complete production halls)
  • Large: 1,000-5,000m (cross-plant logistics)
  • Very large: Over 5,000m (campus solutions)

Technical aspects for long distances:

  • Segmented drives for optimum load distribution
  • Several control areas with central coordination
  • Buffer zones for maintenance without total shutdown
  • Redundant interpretation of critical sections

Planning long distances:

  • 3D simulation of the entire route
  • Optimization of the flow velocities
  • Consideration of building transitions
  • Weather/temperature compensation for outdoor routes

Expandability:
New sections can be added to existing systems at any time – without disrupting ongoing operations.

Can different SCHÖNENBERGER systems be combined?2026-04-02T10:21:09+02:00

Yes, all SCHÖNENBERGER systems are deliberately designed to be compatible and can be flexibly combined. This enables customized overall solutions.

Typical system combinations:

Omniflo + ILS 2100:

  • Omniflo for manual batch compilation
  • ILS 2100 for automatic sequencing
  • Seamless transition between systems

ILS 2100 + ILS pocket sorter:

  • ILS 2100 for hanging garment sorting
  • Pocket sorter for flat goods integration
  • Joint control and IT integration

Omniflo + CPC:

  • Omniflo in workspaces
  • CPC for transport routes and buffers
  • Optimal balance of flexibility/automation

All systems + ASRS:

  • Vertical storage with high-bay connection
  • Automatic storage/retrieval
  • Maximum use of space

Advantages of the combination:

  • Optimal solution for every process step
  • Step-by-step automation possible
  • Investment protection through expandability
  • One contact for all systems

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Do you have any further questions about overhead conveyor technology?

We will be happy to help you!

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