In 2019, TMS successfully designed and manufactured a heavy-duty roller conveyor system for the Pepsi factory in Tanta, specifically for handling and transporting pallets of mineral water bottles. The project involved designing a product that matched the performance and quality of a roller conveyor manufactured by the European company Krones, customized to the factory’s specific operating requirements.

The conveyor was 13 meters in total length, divided into six modular sections of 2 meters each and one section of 1 meter. With a width of 1.2 meters, it was engineered to seamlessly accommodate Euro-standard pallets loaded with water gallon bottles. Each roller had a diameter of 90 mm, manufactured from high-grade stainless steel to ensure both strength and resistance against corrosion from water exposure.

The rollers were fitted with precision-machined sprockets (“double-sprocket gears”) and were interconnected via a high-strength chain drive system. This design ensured synchronized movement across all rollers, distributing the mechanical load evenly and reducing wear. The chain-and-sprocket configuration was powered by a heavy-duty industrial gearbox with sufficient torque to continuously move pallets weighing 1 to 1.5 tons each over long operating shifts.

The chassis of the conveyor was constructed from 8 mm thick stainless-steel beams, designed to withstand the constant dynamic stress of moving tonnage loads without deformation. The modular design allowed for easier installation, future expansion, and simplified maintenance access.

Given the harsh working conditions of beverage plants—high humidity, frequent washing, and exposure to spills—the entire conveyor was designed to meet food industry hygiene standards. Smooth weld finishes, accessible cleaning points, and open-frame architecture minimized bacterial buildup and facilitated CIP (clean-in-place) operations.

From an operational standpoint, this roller conveyor connected the filling station (filler area) to the loading zone, bridging a critical material handling gap. Its reliability ensured uninterrupted movement of heavy pallets over a considerable distance, significantly improving throughput and reducing reliance on forklifts for internal transport.

Since installation, the system has operated with minimal maintenance, requiring only scheduled lubrication and chain tension adjustments. The project was a clear demonstration of TMS’s ability to engineer robust, European-quality conveying solutions, tailored for the unique demands of high-volume beverage production in Egypt.