Power and free conveyors are a highly flexible and intelligent transport system widely used in modern coating lines—including powder coating, liquid painting, and electrophoretic deposition (e-coating). Unlike conventional continuous conveyors, they enable individual carriers to start, stop, accumulate, or reroute independently, offering unmatched efficiency and adaptability.

What Is a Power and Free Conveyor?

A power and free conveyor features two parallel tracks:

• Power Track (upper): Moves a continuously running chain.

• Free Track (lower): Carries individual trolleys that engage or disengage from the power chain as needed.

Each trolley is equipped with flippers that interact with the pusher dogs on the power chain to control motion. Stop stations allow trolleys to pause without interrupting overall system movement, enabling smart accumulation and process control.

Key Advantages in Coating Applications

1. Space-Saving Design

Power and free conveyors make efficient use of vertical and horizontal space. Over/under configurations can reduce floor space requirements by up to 50%, ideal for facilities with limited layout flexibility.

2. Improved Throughput

Because trolleys operate independently, slow processes like curing or robotic spraying no longer create bottlenecks. This dynamic flow can significantly increase line capacity and overall productivity.

3. Energy Efficiency

Only the required sections of the line are active at any time. With zone control, smart drives, and optional gravity-based accumulation zones, energy use can be cut by up to 50%.

4. Versatile Part Handling

The system supports a wide range of part sizes, weights, and process sequences—whether for pre-treatment, coating, drying, or curing. It's ideal for high-mix, multi-shift production and can easily integrate with robotics or dipping cranes.

Core Features Designed for Coating Environments

• Anti-static, heat- and corrosion-resistant chains for coating booths and curing ovens

• Vibration-free operation for consistent, defect-free finishes

• Drive and tension systems with load-specific placement and variable frequency drives (VFDs)

• Automatic lubrication units to extend equipment lifespan

• Modular components including stop stations, switches, lift/drop units, rotation devices, and more

The system can be configured with slot-down (trolley beneath the track) or slot-up designs for cleanroom-quality applications where zero contamination is tolerated.

When to Use a Power and Free Conveyor

Although power and free systems require higher initial investment compared to simple overhead conveyors, they provide excellent ROI for:

• Complex, multi-stage coating processes

• High-value or large-volume products

• Flexible, high-mix production environments

• Layouts requiring precise part flow control​

Information Required for System Design

To develop an optimal conveyor solution, suppliers typically need:

• Part dimensions and maximum weight

• Required production throughput

• Process description (e.g. manual/robotic spraying, curing ovens, etc.)

• Accumulation or switch needs

• Desired conveyor path or facility layout

Conclusion

From powder and liquid coating to e-coating systems, power and free conveyors provide the flexibility, precision, and efficiency needed for modern automated finishing lines. Whether you're upgrading an existing plant or building a new one, this system offers long-term benefits in productivity, space optimization, and process control.