The Real Cost of Inefficient Material Handling

Before we get into products, let’s name the actual problems warehouse operators face day-to-day:

• • Labour dependency and rising wage costs. Manual pick-and-carry operations are expensive and inconsistent. As wages rise and labour availability tightens, operations built around human movement of goods become progressively harder to scale.

• • Throughput bottlenecks. A fast picking operation does nothing if goods pile up between zones. Poorly designed flow between receiving, storage, picking, and despatch creates invisible queues that kill fulfilment speed.

• • Order accuracy issues. Manual handling at every stage multiplies the points at which errors occur. Mis-picks, mis-routes, and missed scans are almost always flow and process problems — not people problems.

• • WH&S compliance gaps. Manually moving heavy cartons, pallets, and totes creates injury risk. Conveyors don’t just improve efficiency — they remove your most common sources of musculoskeletal strain claims.

• Inability to scale with volume. E-commerce order volumes don’t spike predictably. A system that can’t scale for peak periods forces either over-hiring or under-fulfilment.

These aren’t abstract concerns. They’re the specific operational pain points that Interroll’s conveyor platforms are engineered to address.

What Are Interroll Conveyor Systems?

Interroll is a Swiss-headquartered global manufacturer of conveyor and material handling technology, operating in over 40 countries. Their conveyor platforms are used in some of the world’s most demanding logistics, e-commerce, food processing, and airport environments.

What sets Interroll apart from generic conveyor suppliers is their modular platform philosophy: systems are designed to be expanded, reconfigured, and integrated with robotics and warehouse management software — not locked into a single layout.

SAS partners with Interroll to supply, design, and install their systems for Australian businesses.

Interroll Conveyor Platform Guide

Interroll Conveyor Platform Guide

Best for: Unit handling, carton and tote movement, zone picking, goods-to-person systems The MCP is Interroll’s flagship platform and the industry standard for modular conveyor systems in unit and container handling. It uses decentralised controls and zero-pressure accumulation (ZPA) — meaning products queue without contact, preventing damage and reducing jam events.

Key capabilities:

• Scalable from single-zone to enterprise-wide networks
• Compatible with robotic picking integrations
• Decentralised RollerDrive units reduce energy consumption
• Supports WCS, PLC, and standalone card logic deployment

The problem it solves: You have multiple warehouse zones — receiving, pick faces, packing, despatch — and goods need to flow between them reliably without constant manual intervention or the risk of product damage. The MCP creates a controlled flow network that connects those zones.

2. MCP PLAY — The Next-Generation Modular Platform

Best for: Fast-growing operations that need speed and simplicity during deployment MCP PLAY is Interroll’s evolved version of the MCP platform, engineered for faster installation, simpler commissioning, and smarter integration. For operations in rapid growth phases, MCP PLAY reduces the complexity typically associated with deploying modular conveyor networks.

The problem it solves: You need to get a conveyor system running fast and expect to expand it as the business grows. Traditional conveyor installations are slow to commission and rigid once deployed — MCP PLAY addresses both constraints.

3. HPP — High Performance Conveyor Platform

Best for: High-volume e-commerce, parcel handling, courier and express operations The HPP is built for throughput. It handles packages, parcels, and polybags at high speed without compromising reliability. For operations processing thousands of items per shift, the HPP provides the mechanical durability and control precision to keep pace.

Key capabilities:

• Engineered for high-cycle, continuous operation
• Handles mixed product profiles including soft bags and irregular parcels
• Designed to integrate with automated sorting and scanning systems

The problem it solves: Your current conveyor system can’t keep up with volume during peak periods, or it breaks down under sustained high-cycle loads. The HPP is the platform for operations where throughput is the primary constraint.

4. MPP — Modular Pallet Platform

Best for: Receiving, palletising, de-palletising, storage induction, and outbound staging The MPP handles full pallet transport through your facility. The standard configuration supports loads up to 500 kg, while the heavy-duty variant manages up to 1,500 kg — covering the vast majority of pallet profiles used in Australian warehousing.

Key capabilities:

• Positional accuracy within ±1 mm for precise pallet placement
• Fast transfer cycles with high reliability
• Compact profiles that integrate into tight facility layouts
• Compatible with automated storage and retrieval systems (ASRS)

The problem it solves: Your pallet movements — from dock to storage, storage to production, and production to despatch — are handled manually or with forklifts, creating congestion, safety risks, and throughput constraints. The MPP removes forklifts from internal flows and replaces them with consistent, controlled pallet movement.

5. SHC — Special Hygienic Conveyor

Best for: Food processing, beverage production, pharmaceutical handling The SHC is a stainless steel conveyor platform engineered specifically for hygiene-intensive environments. Every design decision — from drain angles to material selection — is made for compliance with cleaning-in-place (CIP) protocols and food safety standards.

Key capabilities:

• Full stainless steel construction
• Open design for thorough washdown access
• Compliant with hygiene regulations for food and pharmaceutical environments

The problem it solves: Standard conveyors cannot be adequately cleaned in food-processing environments, creating contamination risk and compliance failures. The SHC provides conveyor capability without compromising hygiene standards.

How SAS Designs and Deploys Interroll Systems

Buying conveyor equipment is not the same as having a working conveyor system. The gap between those two things is design, engineering, project management, and integration — and it’s where most automation projects succeed or fail.

SAS brings 80 years of combined industry experience to every project. Our process:

1. Facility and flow audit We map your current material flows, identify bottlenecks, measure throughput requirements, and establish your peak volume scenarios. The design is built around your specific operation — not a generic template.
2. System design and specification We select the appropriate Interroll platform (or combination of platforms), configure the layout, specify controls and integration requirements, and produce a detailed design for client review.
3. Project management and installation Our team manages procurement, site preparation, installation, and commissioning. We coordinate with your warehouse management system (WMS) vendor and any existing automation to ensure clean integration.
4. Handover and ongoing support We commission the system, train your team, and provide ongoing support. A conveyor system should reduce your operational complexity — not create a new one.

Choosing the Right Conveyor System: A Decision Framework

Recommended Platform and Recommended Platform

If your requirements span multiple categories — for example, a distribution centre running both carton picking and full-pallet inbound — SAS designs hybrid systems that combine platforms within a single integrated flow.

Industries We Serve With Interroll Conveyor Solutions

• Warehousing and Distribution From single-warehouse operations to multi-site distribution networks, Interroll’s modular platforms scale with your volume and integrate with leading WMS and WCS platforms.

• E-Commerce and Retail Fulfilment High SKU counts, variable order profiles, and peak-period volume spikes require flexible, high-throughput conveyor systems. The MCP and HPP platforms are both proven in e-commerce environments globally.

• Food and Beverage The SHC platform meets the hygiene requirements for food-grade conveyor handling — including washdown environments and temperature-controlled facilities.

• Manufacturing Logistics Intralogistics flow between production cells, kitting areas, and outbound staging benefits from the reliability and precision of Interroll’s pallet and unit platforms.

• Courier, Express, and Parcel (CEP) Parcel operations running continuous high-volume shifts require conveyors engineered for durability. The HPP is used globally by major logistics operators in CEP environments.

Frequently Asked Questions About Interroll Conveyor Systems

What is the Interroll Modular Conveyor Platform (MCP)?

The Interroll MCP is a scalable, modular conveyor system for moving cartons, totes, and boxes in warehouse and distribution environments. It uses decentralised RollerDrive technology and zero-pressure accumulation to move goods without contact between items, reducing damage and enabling flexible routing.

How much weight can Interroll pallet conveyors handle?

Interroll’s MPP (Modular Pallet Platform) handles loads up to 500 kg in the standard configuration and up to 1,500 kg in the heavy-duty variant.

Can Interroll conveyor systems integrate with warehouse management systems (WMS)?

Yes. Interroll conveyor systems can be controlled via PLC, Warehouse Control System (WCS), or standalone card logic, and are designed to interface with leading warehouse management and execution systems.

What industries use Interroll conveyor systems?

Interroll conveyors are deployed across warehouse and distribution, e-commerce fulfilment, food and beverage, pharmaceutical, manufacturing logistics, courier/parcel operations, and airport baggage handling.

What is zero-pressure accumulation (ZPA) in conveyor systems?

Zero-pressure accumulation means products queue on a conveyor without making contact with each other. Sensors detect downstream gaps and stop individual conveyor zones to hold items in place until space is available, preventing product damage from pile-up collisions.

Does SAS install Interroll conveyor systems in Australia?

Yes. SAS (Smarter Automated Solutions) is an authorised Interroll partner supplying, designing, and installing Interroll conveyor systems for Australian businesses. Contact our team for a facility consultation.

Start With a Conversation

Every facility is different. Throughput requirements, product profiles, available floor space, and integration requirements all shape which Interroll platform — or combination of platforms — is right for your operation.

The fastest way to identify the right solution is to walk through your current operation with our team. We’ll identify the specific friction points in your material flow and give you a clear view of what a properly designed conveyor system would change.

Get in touch with SAS:

• Email: sales@smarteras.com.au
• Mobile: 0423 552 542

Or visit our Conveyor Solutions page to learn more about how we deploy carton conveyors, pallet conveyors, and sortation systems for Australian warehouses.