{"id":25237,"date":"2022-07-12T07:00:28","date_gmt":"2022-07-12T12:00:28","guid":{"rendered":"https:\/\/www.cisco-eagle.com\/blog\/?p=25237"},"modified":"2025-09-05T08:49:22","modified_gmt":"2025-09-05T13:49:22","slug":"gapping-conveyors-a-guide-to-types-and-applications","status":"publish","type":"post","link":"https:\/\/www.cisco-eagle.com\/blog\/2022\/07\/12\/gapping-conveyors-a-guide-to-types-and-applications\/","title":{"rendered":"Gapping Conveyors: A Guide to Types and Applications"},"content":{"rendered":"<p><img decoding=\"async\" style=\"width: 100%; max-width: 700px; height: auto; margin-bottom: 12px; margin-top: 12px;\" src=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2022\/06\/gapper-conveyor.jpg\" alt=\"Gapper Conveyor line in a distribution center\" \/><\/p>\n<div data-amp-original-style=\"text-align: left;\">Conveyors that create gaps between loads\u2014<a href=\"https:\/\/www.cisco-eagle.com\/category\/3268\/power-belt-gapping-conveyor\">called &#8220;gappers&#8221;<\/a>\u2014are used in functions ranging from sortation to quality control to packing to machine integration. Any process that requires identical and predictable gaps between the back of a load and the leading edge of the following will probably need a gapper. Most gappers are <a href=\"https:\/\/www.cisco-eagle.com\/category\/1148\/belt-conveyors\">slider bed belt conveyors,<\/a> since belts provide superior control and support.<\/div>\n<p><!--more--><\/p>\n<div class=\"amp-wp-102b7f8\" data-amp-original-style=\"text-align: left;\">\n<div style=\"padding: 20px; border-radius: 15px; border: 2px solid #E4DDDD; margin: 4px 10px 4px 10px; box-shadow: 0 4px 8px 0 rgba(0, 0, 0, 0.2), 0 6px 20px 0 rgba(0, 0, 0, 0.19);\">\n<h3>TL;DR: What are gappers?<\/h3>\n<ul>\n<li>Gappers combine two separate belts that convey at different speeds, which creates a gap between loads on the conveyor.<\/li>\n<li>Gappers are slider bed conveyors, and are considered an accessory that functions in a broad variety of applications.<\/li>\n<li><strong>Blow-through type gappers<\/strong> are more basic, less expensive and simpler. They run at fixed speeds that create the gaps necessary for the next process on a conveyor line. They&#8217;re used for applications that transport or sort uniform loads in size and type. A distribution center that ships out only one or a very limited range of cartons is a good example of a blow-through application.<\/li>\n<li><strong>Gap optimizers<\/strong> are faster, more expensive and provide better throughput for a broader variety of loads. These gappers create uniform spaces between loads of different dimensions and weights. Optimizers adjust their speed based on sensors and control protocols. They&#8217;re often deployed for high-throughput, e-commerce and 3PL applications that require variability and speed.<\/li>\n<\/ul>\n<\/div>\n<h3>Sortation gaps<\/h3>\n<p>Because sortation systems need to scan and divert cartons at high speeds, they&#8217;ll need a gapping conveyor to ensure fast and accurate throughput before loads enter a sort zone. Many types of sorters need uniform gaps to correctly scan and divert loads. This also helps increase a sorter&#8217;s throughput and reliability.<\/p>\n<\/div>\n<div class=\"amp-wp-102b7f8\" data-amp-original-style=\"text-align: left;\">\n<h3 class=\"amp-wp-102b7f8\" data-amp-original-style=\"text-align: left;\">Machines and packaging integration<\/h3>\n<p>Processing packages through an insert void filler, passing through a scan tunnel, applying a label, taping a carton top, shrink wrapping a load or any other number of packaging functions can require precise gaps. These gaps allow time for the process to execute before the next carton enters the machine. You can sometimes do this with accumulation buffers, but a gapping solution upstream of the packaging machine often works better and more reliably.<\/p>\n<p class=\"amp-wp-102b7f8\" data-amp-original-style=\"text-align: left;\">Adequate gaps give packages room to turn during merging and combining. The gaps give your system time to print and apply labels, for camera systems to read barcodes, weigh packages, or create proper spacing for the sorter to operate.<\/p>\n<h4 data-amp-original-style=\"text-align: left;\">What are your gapping application considerations?<\/h4>\n<ul>\n<li>The load profile: dimensions, weight and other characteristics of all loads on the conveyor system<\/li>\n<li>How much gap will you need between items? Is it always the same?<\/li>\n<li>What happens after the gap&#8211;sortation, machinery, manual processes, sensors, etc?<\/li>\n<li>What else in the design and overall flow should you consider?<\/li>\n<\/ul>\n<\/div>\n<p><img decoding=\"async\" style=\"width: 100%; max-width: 700px; height: auto; margin-bottom: 12px; margin-top: 12px;\" src=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2022\/06\/Gapper-Conveyor-Diagram.jpg\" alt=\"How gaps are set, before and after gapping conveyor equipment. Labels include Space pre-gapper, box length, flow direction, and final gap between cartons \" \/><\/p>\n<h3>Other applications for gappers<\/h3>\n<ul>\n<li>Use gappers to separate cartons for some manual operations, allowing operators to easily access loads with consistent gaps between them. This gives a worker time to grab, inspect, rotate, fill, assemble or perform other functions.<\/li>\n<li>Gaps are also necessary for sawtooth merges and some spurs.<\/li>\n<li>You may need to create gaps ahead of sensors or scanners on your conveyor system.<\/li>\n<li>Gaps may be useful for some pushers or rotators.<\/li>\n<li>Gappers are often used preceding inline scales.<\/li>\n<\/ul>\n<blockquote><p><em>Gappers create precise, uniform gaps to help facilitate a variety of functions downstream of them on the conveyor. Using a gapper helps you create consistency and faster, more reliable operation for machine integrations, sorters and manual processes.<\/em><\/p><\/blockquote>\n<div style=\"padding: 20px; border-radius: 15px; border: 2px solid #E4DDDD; margin: 4px 10px 4px 10px; box-shadow: 0 4px 8px 0 rgba(0, 0, 0, 0.2), 0 6px 20px 0 rgba(0, 0, 0, 0.19);\">\n<div class=\"row\">\n<div class=\"col-sm-4\">\n<p><a href=\"https:\/\/www.cisco-eagle.com\/uploads\/brochures\/conveyor-buyers-guide.pdf\"><img decoding=\"async\" style=\"float: right; width: 100%; max-width: 200px; height: auto; margin-left: 20px; margin-right: 18px;\" src=\"https:\/\/images.cisco-eagle.com\/blog\/wp-content\/uploads\/2020\/06\/Conveyor-Guide-Cover.jpg\" alt=\"Cisco-Eagle conveyor system guide\" \/><\/a><\/p>\n<\/div>\n<div class=\"col-sm-8\">\n<div class=\"row\">\n<h3><a href=\"https:\/\/www.cisco-eagle.com\/uploads\/brochures\/conveyor-buyers-guide.pdf\" target=\"_blank\" rel=\"noopener\">Download Cisco-Eagle&#8217;s guide to conveyors &amp; systems<\/a><\/h3>\n<p>Well-executed conveyors and systems will optimize your operation&#8211;and we can help you make that happen. Cisco-Eagle&#8217;s detailed guide to conveyors gives you advice from our expert employee-owners, links, articles and more.<\/p>\n<h4><a href=\"https:\/\/www.cisco-eagle.com\/uploads\/brochures\/conveyor-buyers-guide.pdf\" target=\"_blank\" rel=\"noopener\"><strong><em>Download the guide <\/em><\/strong><strong><em>today<\/em><\/strong><\/a><\/h4>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>Conveyors that create gaps between loads\u2014called &#8220;gappers&#8221;\u2014are used in functions ranging from sortation to quality control to packing to machine integration. Any process that requires identical and predictable gaps between the back of a load and the leading edge of the following will probably need a gapper. Most gappers are slider bed belt conveyors, since [&hellip;]<\/p>\n","protected":false},"author":2,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[3],"tags":[],"series":[],"class_list":["post-25237","post","type-post","status-publish","format-standard","hentry","category-conveyor"],"acf":[],"aioseo_notices":[],"publishpress_future_action":{"enabled":false,"date":"2027-04-15 04:08:15","action":"change-status","newStatus":"draft","terms":[],"taxonomy":"category","extraData":[]},"publishpress_future_workflow_manual_trigger":{"enabledWorkflows":[]},"_links":{"self":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts\/25237","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/comments?post=25237"}],"version-history":[{"count":27,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts\/25237\/revisions"}],"predecessor-version":[{"id":32857,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/posts\/25237\/revisions\/32857"}],"wp:attachment":[{"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/media?parent=25237"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/categories?post=25237"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/tags?post=25237"},{"taxonomy":"series","embeddable":true,"href":"https:\/\/www.cisco-eagle.com\/blog\/wp-json\/wp\/v2\/series?post=25237"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}