Manufacturer of MDR Merge Spur Conveyors
Product Overview:
AstraRoll is a premier manufacturer and supplier of Custom 24V MDR (Motor-Driven Roller) Merge Spurs, designed to seamlessly combine product flows in high-throughput distribution and fulfillment centers. Operating on a decentralized 24V DC brushless motor platform, our merge spurs utilize intelligent "Run-on-Demand" logic, activating zones only when a parcel is present. This drastically reduces energy consumption by up to 70% compared to continuously running AC motors. Specifically engineered for Zero-Pressure Accumulation (ZPA), AstraRoll MDR modules ensure fragile cartons and polybags merge onto the mainline without colliding, eliminating product damage. As a factory-direct partner, we custom-build every spur frame and roller matrix to match your precise facility layout (30° or 45° angles), providing systems integrators with a true "plug-and-play" module that interfaces effortlessly with existing WMS and PLC networks.
Roll Function:
Industry Applications: Logistics Conveyor Systems, Packaging
Manufacturer of MDR Merge Spur Conveyors Details
Product Features & Engineering Specs
High-Speed Throughput Capability: Precision MDR zoning allows for seamless, high-rate package induction, safely merging up to 40 to 60 cartons per minute (CPM) onto the mainline depending on parcel length.
Plug-and-Play Architecture: Every module is factory-wired with standard industrial driver cards and M8/M12 quick-connect cables. Integrators can bolt the spur to the mainline and daisy-chain the power/logic in minutes, bypassing the need for expensive field wiring.
Ultra-Safe 24V Operation: The low-voltage DC architecture minimizes arc-flash risks and eliminates the need for heavy, high-voltage safety guarding, making it exceptionally safe for human operators to work alongside.
Industrial-Grade Construction: Built with heavy-gauge 10-D or 8-D powder-coated steel side channels and precision ABEC-1 bearings, designed to withstand 24/7 continuous shift operations.
Agile PLC Handshaking: Onboard control cards offer standard I/O, Ethernet/IP, or PROFINET communication, allowing your centralized WCS (Warehouse Control System) to dictate dynamic merge priorities on the fly.
Key Attributes
Standard Roller: 1.9" (50mm) Galvanized Steel or Polyurethane-Sleeved.
Drive Mechanism: 24V DC Brushless Motor-Driven Roller (MDR) with O-ring/Poly-V belts.
Merge Angles: Custom-engineered (Typically 30° or 45°).
Conveying Speed: Variable, up to 200 FPM (60 meters/minute).
Load Capacity: Up to 100 lbs (45 kg) per zone (Medium Duty).
Control Logic: Built-in ZPA (Zero Pressure Accumulation) with pre-wired photo-eyes.
Frame Material: Powder-Coated Steel, Aluminum, or Stainless Steel.
Why Choose AstraRoll? (Your B2B Partner)
Factory-Direct Customization
OEM Module Supply: We build "white-label" or custom-branded merge modules for global systems integrators. You provide the layout dimensions, and our factory provides the fully assembled, pre-tested hardware.
Flexible Drive Compatibility: We can equip our frames with industry-standard rollers and control cards (such as Itoh Denki, Interroll, or PulseRoller) based on your facility's existing spare-parts inventory, ensuring total fleet compatibility.
Engineering Expertise
Seamless Mainline Integration: We don't just sell the spur; we can supply the corresponding "receiver" mainline section, ensuring the roller spacing and transition plates are perfectly matched to prevent polybag snagging at the intersection.
Frequently Asked Questions (FAQ)
Q: Can MDR merge spurs handle flexible polybags and envelopes?
A: Yes. For polybag applications, we utilize tighter roller centers (e.g., 2" or 3" spacing instead of standard 4") and often apply high-grip polyurethane sleeves to the rollers to ensure lightweight, irregular packages don't slip or fall between gaps during the merge.
Q: Do I need a central PLC to control the Zero-Pressure Accumulation?
A: No. Our standard MDR driver cards feature "built-in" ZPA logic. Once you daisy-chain the zones together, they automatically communicate with each other to manage accumulation without requiring a master PLC. However, a PLC can be used if you want to apply complex routing or priority-merge rules.
Q: What maintenance is required for MDR systems?
A: Very little. Unlike chain-driven systems, there are no sprockets to grease or chains to tension. The brushless 24V motors are sealed for life. The only routine maintenance involves visually inspecting the photo-eyes for dust and occasionally replacing a snapped O-ring drive band.
Q: Can you manufacture these spurs in stainless steel for food environments?
A: Yes. As a custom manufacturer, we can build the entire frame out of 304 Stainless Steel and utilize IP66-rated washdown MDR rollers and waterproof sensors for strict sanitary compliance.
Q1. Are you a trader or direct factory?
We are a real factory with more than 20 years experience in producing blister packaging.
Q2. What are your main products?
We design and manufacture a full range of custom packaging solutions, including food packaging (bakery, takeout, drink, meat, seafood, supermarket etc.), as well as electronic, cosmetics, agricultural packaging and so on, offering one-stop services from design and mold development to production.
Q3. What about delivery time?
1-3 working days for proofing. 7-15 working days for quality quantity depends on the order quantity after you confirm the sample.
Q4. How can I get a quote for customized products?
The exact price will be determined based on your specific requirements, including the product's dimensions (length, width, height, thickness), material selection, order quantity, packaging method, and any printing or logo customization needs.
Q5. What is your payment?
TT / Paypal / Western Union / LC / Credit Card etc. are all available to us.
