Small products like chocolates, iced cookies, and pet treats can lose their spacing in the gap between two conveyors. A knife edge conveyor fixes this with infeed and discharge nose bars that have a very small radius, which can cut the transfer gap to less than 1/2 inch.
At D&R Packaging, we build these tight transfer conveyors to move small goods in bulk with their spacing and orientation intact. Below, we explain what a knife edge conveyor is and how we build ours.
What is a Knife Edge Conveyor and What Defines It?
A knife edge conveyor, also called a tight transfer conveyor, is defined by infeed and discharge nose bars with a very small radius. These thin nose bars let products pass from one conveyor to the next across a short gap.
We build our knife edge conveyors with one of two nose bar options.
3/8-Inch Static Nose Bar
The static option uses a 3/8-inch-diameter nose bar. It is the smaller of our two options, and the transfer figures in the next section are based on it.
7/16-Inch Live Roller Bearing Nose Bar
The live option uses a 7/16-inch-diameter nose bar that turns on roller bearings. Its radius is still small enough to create a tight transfer.
How Tight Transfers Handle Small Products
The smaller the gap between two conveyors, the shorter the product that can cross it smoothly. Here is how that works with our 3/8-inch nose bar.
Transfers with Both Conveyors on the Same Plane
On two inline conveyors, the distance from the apex of one nose bar to the next can be less than 1/2 inch. Both conveyor tops sit on the same plane. This setup lets products as short as 1 inch transfer smoothly.
Transfers with a Small Cascade
We can shorten that minimum further. If the infeed conveyor discharges just 3/8 inch higher than the trailing conveyor, products as short as 3/4 inch transfer smoothly with only a small cascade.
| Transfer setup (3/8 in nose bar) | Height difference | Shortest product that transfers smoothly |
| Both conveyor tops on the same plane | None | 1 in |
| Infeed discharges above the trailing conveyor | 3/8 in | 3/4 in |
Pro Tip: When you request a quote, share the length of your shortest product. That number tells us whether an inline transfer or a small cascade is the better fit.
Industries that Rely on Knife Edge Conveyors
A tight transfer matters most when products are small, delicate, or still cooling. Our knife edge conveyors keep these products spaced and oriented as they move down the line.
What a Knife Edge Conveyor is Used For
Here are a few common examples from our builds:
- Chocolate candies that need time to cool and harden.
- Small baked goods like cookies with a drizzle of icing on top.
- Pet treats that must keep their spacing so they do not stick together.
Industries We Build For
We build knife edge conveyors for customers in these industries:
- Candy
- Pharmaceutical
- Baked goods
- Pet treats
- Small printed goods
Need expert help with a knife edge conveyor? Contact D&R Packaging directly to discuss your project and product requirements.
Knife Edge Conveyor Sizes and Custom Builds
Our knife edge conveyors are built to order in a wide range of widths and lengths.
Size Range We Have Built
Our builds so far include:
- Largest builds: up to 48 inches wide and over 35 feet long.
- Smallest builds: below 12 inches wide and as short as 5 feet long.
Designed Around Each Application
We design and build each conveyor to the customer’s needs. Because every application is different, we rarely get the chance to build multiple identical conveyors.
Key Takeaway: Every conveyor is sized for its application. Share your product and application details, and we will design the conveyor to fit.
Features that Simplify Cleaning and Belt Care
Our knife edge conveyors include features that make cleaning faster and keep the belt on track.
Tool-Free Cleaning Access
- Long-stroke pneumatic tensioners slacken the continuous belt enough for thorough cleaning with no tools.
- Spring-loaded belt scrapers can be removed without tools.
- Cleanout holes in the side frames can stay open or be fitted with doors, based on your preference.
Automatic Belt Tracking
We use automatic belt tracking on most of our knife edge conveyors. After the initial setup, the system keeps the belt running true on its own. We can set it up to track in one direction or automatically in both forward and reverse.
Pro Tip: If your conveyor needs to run in both directions, ask for forward and reverse automatic tracking during the design stage.
Retracting Nose Bar Conveyors for Tray Loading
We can also build knife edge conveyors with a retracting nose bar. This design works especially well for loading trays or transferring products onto perpendicular conveyors.
Protecting Orientation and Fragile Products
A retracting nose bar keeps each product in its original orientation as it leaves the belt. The small-diameter knife-edge nose bar also allows a very small elevation change between the conveyor and the tray, which keeps fragile products from breaking.
Tighter Spacing for Better Topping Coverage
A retracting nose bar conveyor can maintain product spacing or tighten it for the downstream conveyor. Tighter spacing can significantly reduce the amount of topping that misses the product.
Key Takeaway: For tray loading and topping lines, a retracting nose bar protects fragile goods and cuts topping waste.
Talk to D&R Packaging About Your Conveyor Project
The Short Answer
A knife edge conveyor uses a nose bar with a very small radius to create a tight transfer between conveyors. We offer a 3/8-inch static or a 7/16-inch live roller bearing nose bar. With the 3/8-inch option, the gap can be less than 1/2 inch, so products as short as 1 inch transfer smoothly, or 3/4 inch with a small cascade. Add tool-free cleaning, automatic belt tracking, and optional retracting nose bars, and you get a conveyor built for small, delicate goods.
Start Your Project
We design each conveyor to your requirements and application. Contact D&R Packaging today to discuss your project, and our team will show you what a knife edge conveyor can do for your products.
