What is the gap that you should be mindful of when it comes to roller conveyors in the ecommerce world?

Roller conveyor systems, like our Modular Portable Roller Conveyor and Modular Roller Conveyor Plus (MPRC, MPRC+), are very commonly used in distribution and fulfillment centers. As customer use cases evolve, the real challenges often show up in the gaps. This is where our Gap Fillers (patent pending) occupy the space between rollers based on application needs. This not only improves efficiency but also enhances safety for day-to-day operations.

Many fulfillment centers have parcels moving down roller-style conveyance lines by the hundreds, if not thousands, daily. There is a broad range of parcel sizes, types, and weights, including boxes, poly bags, and bubble mailers. What many do not realize is that with this wide variety and constant fluctuation in parcel sizing, there are risks of catch points and even the chance for products to fall through or off the conveyor. This can require stopping the system or having operators retrieve parcels to ensure they continue through the fulfillment process. In high-throughput environments, with shorter handling intervals and more frequent touchpoints, additional safety measures become critical—especially around hair, hands, and loose clothing.

A simple solution that helps reduce downtime, protect equipment, and improve safety

Our Gap Fillers provide a solution to keep parcel handling operations running as smoothly as possible on modular portable roller conveyor systems. We have designed a filler piece that addresses a variety of daily issues in parcel handling environments.

Safety is an everyday concern in ecommerce operations. Using our Gap Fillers to close the space between rollers reduces risk, increases safety, and lowers costs associated with damaged equipment or injury-related downtime.

Efficient operations are equally critical. Every minute of uptime in a fulfillment center matters. With a wide range of parcel sizes moving across conveyors—and more variation being introduced daily through ecommerce—systems must effectively handle it all. Smaller or irregularly shaped parcels can get caught in gaps, fall through, or become stuck at various points. Our Gap Filler solution ensures parcels stay on track.

In bulk flow conditions, where items may be spread across or stacked on conveyors, evenly distributed pressure across rollers is essential. Our Gap Fillers help maintain balanced weight distribution as items move, reducing catch points and preventing delays. This keeps parcels moving smoothly, minimizes the need for manual intervention, and eliminates unnecessary downtime. Additionally, the fillers are easily removable for maintenance and contribute to lower operating costs overall.

Ease of integration is another key advantage. Our Gap Fillers are designed not only for our existing customers but also for those using other conveyor systems. We can tailor solutions to fit your current setup. Installation is straightforward—simply tap the male and female brackets into place on each end, then use our installation and removal tool to secure the Gap Filler.

This process can typically be completed in just ten minutes per 12-foot section with two people. We have continuously improved our installation tool over the past four years, now in its third generation, demonstrating our commitment to innovation and ease of use. The goal has always been to simplify operations while improving safety.

From an efficiency standpoint, our Gap Fillers offer a quick, deployable solution to keep roller conveyor systems running at peak performance. When parcels get caught or fall between rollers, they can become damaged, leading to rework, additional handling, and delays in delivery. Our solution helps eliminate these issues.

We can customize Gap Fillers to your exact system specifications, whether you use our conveyors or another provider’s. Installation is faster compared to other solutions and can even be completed by a single person. The fillers can also be removed easily for maintenance. We are also able to service fillers even if they are not LogistiQ products, we are able to agnostically retrofit. Most importantly, they provide peace of mind by significantly reducing safety risks for associates.