Metal Structures for FMCG DCs: Conveyors and Protection

The Role of Metal Solutions in FMCG Distribution Centers

An FMCG distribution center is not just a warehouse, but a flow-based system where every second of order processing affects turnover and cost price. The metal structures of conveyors, guides, and protective barriers form the “skeleton” of this system:

• define the geometry and elevation marks of conveyor lines;
• ensure safe movement of containers, pallets, and personnel;
• protect equipment, racks, and forklift aisles;
• allow scaling and reconfiguring flows as volumes grow.

For Tashkent and Uzbekistan as a whole, an additional factor is climate and dustiness. The choice of materials, welding technology, quality of powder coating, and fastening assemblies determines how long the metal structures will retain their geometry and appearance under intensive operation.

Types of Conveyor Metal Structures for DCs

In an FMCG DC, “conveyor metal structures” usually means not only the conveyor itself, but the entire supporting complex:

1. Supporting frames and conveyor supports

• frames for belt and roller conveyors;
• adjustable supports for height leveling;
• cantilever structures above work areas and walkways;
• service platforms and walkways.

Frames are made from profile tube and sheet metal using laser cutting, metal bending, and welding. For areas with high humidity and frequent washing, stainless-steel solutions are possible—especially if the DC is combined with food production.

2. Transition sections and junction assemblies

• transitions between different types of conveyors (belt → rollers, rollers → sorter);
• curved sections and S-shaped transitions;
• width adjustment assemblies and guide sides.

Such elements are often custom-made to the dimensions of existing equipment. Accuracy is critical: geometric errors lead to container jamming, increased roller wear, and line downtime.

3. Frames for peripheral equipment

• metal structures for scanners, scales, and label printers;
• stands for sensors and photoelectric cells;
• frames for displays and visualization systems.

The key task here is to ensure rigidity and stability of equipment positioning while maintaining access for maintenance and adjustment.

Guides, Barriers, and Flow Control Elements

In an FMCG DC, not only speed but also flow controllability is important. Metal guides and barriers make it possible to control the movement of cartons, pallets, and carts without complex automation.

Conveyor guides

• side guides for stabilizing containers;
• central flow dividers;
• adjustable bumpers in line merge and split zones.

They are made from carbon-steel profiles with powder coating or stainless-steel elements—if increased corrosion resistance or contact with food packaging is required.

Guides and barriers for floor transport

• impact barriers along racks and columns;
• guides for carts and pallet jacks;
• pallet overhang stoppers in racks.

These elements reduce the risk of damage to racks, conveyors, and utility systems during forklift operation. The structures must withstand repeated impacts—properly calculated profile sections and high-quality welding are crucial.

Accumulation zones and buffer sections

Metal guides and stoppers are used to form buffers:

• accumulators before sorting sections;
• waiting zones in front of loading gates;
• returnable packaging buffers.

The structures of such zones are usually calculated according to the TS, taking into account container dimensions, weight, and operating scenarios.

Protective Fencing and Personnel Safety

Protective fencing in an FMCG DC solves several tasks at once:

• physical separation of personnel from moving conveyor parts;
• protection from falling containers from height;
• zoning of access (service personnel only, equipment only, etc.).

Types of protective metal structures

• mesh fencing along conveyors and sorters;
• solid metal screens in areas with possible container ejection;
• guardrails on service platforms and walkways;
• gates with the option to integrate limit switches.

Material and design are selected according to the TS: height, mesh cell size, type of floor or conveyor frame mounting, disassembly requirements.

Design specifics for FMCG

• high equipment density: fencing must account for narrow aisles and evacuation routes;
• frequent line reconfigurations: structures must allow dismantling and relocation of sections;
• interaction with safety systems: provision for cable ducts, sensors, and interlocks.

When designing, it is important to coordinate in advance with automation engineers where sensors, panels, and control cabinets will be installed so that fencing does not obstruct access.

Integration of Metal Structures with Existing Warehouse Infrastructure

In most projects in Tashkent, we are not talking about a “greenfield” site, but about upgrading existing warehouses to the FMCG DC format. This imposes constraints on metal structures:

• tying into existing racks and building columns;
• accounting for existing gates, docks, and floor levels;
• integration with already installed conveyors and lifts.

Key integration points

1. Measurements and 3D model

   Accurate measurements and, if possible, a 3D model of the area are the foundation of a correct TS. This reduces the risk of clashes during installation and enables commissioning without on-site rework.

2. Height and elevation coordination

   Conveyor, platform, and walkway heights must be coordinated with existing racks, gates, and transport levels. An error of even a few centimeters may require section rework.

3. Interface with utility systems

   When placing metal structures, the following are taken into account:

   • cable duct and air duct routes;
   • fire protection systems;
   • service zones for refrigeration and other process equipment.

Materials and Technologies: From Carbon Steel to Stainless Steel

The choice of material and manufacturing technology directly affects both service life and cost.

Main materials

• Carbon steel — the basic solution for conveyor frames, guides, barriers, and fencing in dry warehouse areas.
• Stainless steel — used in areas with high humidity, frequent washing, and in proximity to food equipment and exposed products.

Processing technologies

• Laser cutting — precise manufacturing of complex-shaped parts, holes, and slots for adjustment.
• Metal bending — forming rigid profiles and reinforcements without excessive welds.
• Welding — assembling frames, structures, and supports according to design loads.
• Powder coating — protective and decorative coating resistant to abrasion and impacts.

For FMCG distribution centers, solutions are often combined: load-bearing elements from powder-coated carbon steel, individual assemblies and zones in contact with food packaging from stainless steel.

Project Stages: From TS to Installation and Commissioning

1. Collection of initial data and TS

At this stage, it is important to define:

• functional tasks of the line (receiving, sorting, picking, shipping);
• dimensions and weight of containers, pallets, and bins;
• required throughput and operating scenarios;
• building constraints (height, columns, existing racks and equipment);
• safety and access zone requirements.

2. Concept and preliminary calculation

A general scheme of metal structures is formed:

• conveyor routing and guide placement;
• protective fencing installation zones;
• standard fastening assemblies to the floor and existing structures.

At this stage, indicative pricing is possible, taking into account selected materials and volumes.

3. Detailed design

Drawings and specifications are developed:

• detailing of frames, fencing, and guides;
• adjustment and fastening assemblies;
• tie-in to floor and rack elevations.

4. Metal structure production

At the production facility, the following are performed:

• laser cutting of blanks;
• metal bending according to drawings;
• welding of assemblies and frames;
• machining and drilling;
• surface preparation and powder coating.

5. Installation and participation in commissioning

Installation includes:

• layout and installation of supports;
• on-site assembly of frames and fencing;
• leveling by height and level;
• interface with conveyor and automated equipment.

If necessary, specialists participate in commissioning to promptly eliminate comments on geometry and fastening.

What Affects Cost: Key Factors

The cost of metal structures for an FMCG DC is formed based on calculations according to the TS. Below are the main factors that determine it.

Without a correct TS, even stating an approximate cost is inappropriate. In practice, the range depends on the combination of these factors and schedule requirements.

Common Mistakes When Ordering Metal Structures for FMCG DCs

1. Incomplete TS for containers and loads
   Only carton dimensions are specified, but not weight, pallet type, and impact load scenarios. As a result—underdesigned profiles, deformations, and unscheduled repairs.

2. Ignoring future expansion
   The line is designed “just enough” for current volumes, with no provision for expansion. Later, metal structures have to be rebuilt instead of simply extended.

3. Lack of coordination with automation
   Metal structures are developed separately from the control system. The result is inconvenient placement of sensors, cabinets, and cable routes.

4. Underestimating safety requirements
   Saving on the height and length of protective fencing, lack of gates with controlled access. This creates risks for personnel and may require rework after an audit.

5. Overly rigid design without adjustments
   Lack of height and width adjustment elements complicates installation and subsequent line reconfiguration.

6. Unrealistic timelines
   Launch planning without accounting for design, production, powder coating, and installation time. This leads to rush work and quality compromises.

7. Choosing materials “with a margin” without calculation
   Using excessively heavy profiles and stainless steel where painted steel is sufficient. The result is an unjustified budget increase without real benefit.

Production Lead Times and Realistic Launch Planning

Timelines depend on project volume and complexity, but when planning for an FMCG DC in Tashkent, several stages should be considered, each taking its own time:

• TS and metal structure layout approval;
• development of drawings and specifications;
• procurement of metal and components;
• production (laser cutting, metal bending, welding);
• surface preparation and powder coating;
• logistics to site and installation;
• participation in commissioning and punch-list elimination.

The earlier the metal structure manufacturer is involved in project discussions, the more accurately real timelines can be estimated and aligned with equipment delivery and DC launch schedule.

FAQ: Answers for Logistics Managers and Automation Engineers

1. Can new metal structures be integrated with existing conveyors?
Yes, provided correct drawings and measurements of the existing line are available. Accurate height, width, and mounting point marks are important so that interfacing proceeds without on-site rework.

2. What data are needed to calculate metal structures according to the TS?
At minimum: floor plan, dimensions and weight of containers/pallets, required throughput, flow diagram, list of existing equipment, safety requirements, and installation schedule constraints.

3. When does it make sense to use stainless steel?
In areas with washing, condensation, temperature fluctuations, and in proximity to food equipment and exposed products. In other areas, carbon steel with quality powder coating is usually sufficient.

4. Can the possibility of future line reconfiguration be provided?
Yes, through modular design, adjustment elements, and standardized fastening assemblies. This must be incorporated into the TS and design at an early stage.

5. How to account for safety requirements when designing fencing?
It is necessary to define hazardous zones, personnel access and maintenance scenarios, and locations of gates and interlocks in advance. This data is reflected in the TS and considered in the metal structure design.

6. How to plan installation if the warehouse continues to operate?
The TS and work schedule should specify permissible time windows, noise and aisle closure constraints. Structures can be designed in sections for phased installation.

7. Can existing racks be used as supports for conveyors and fencing?
Sometimes yes, but only after load calculations and rack condition checks. In some cases, it is safer to provide separate supports so as not to overload the racking system.

8. How to design for resistance to impacts from forklifts and carts?
The TS should specify the type of equipment, loaded weight, and movement scenarios. Based on this data, profile sections, distance from structures to aisles, and type of impact barriers are selected.

How to Request a TS-Based Calculation: What Data to Prepare

To obtain an accurate calculation of metal structures for an FMCG distribution center in Tashkent, it is important to prepare a structured TS.

Recommended data set for calculation:

1. General project information

   • area purpose (receiving, sorting, picking, dispatch);
   • new DC or upgrade of an existing warehouse;
   • planned launch dates.

2. Layout and building constraints

   • floor plan with dimensions and elevation marks;
   • location of columns, gates, docks, racks;
   • zones where installation is impossible or limited.

3. Containers and flows

   • types of containers (cartons, crates, pallets, bins);
   • dimensions and weight (minimum/maximum);
   • required throughput for each line.

4. Required metal structures

   • conveyor frames and supports (type, approximate length);
   • guides and barriers (for conveyors and floor transport);
   • protective fencing (approximate length and height, installation zones);
   • platforms, walkways, stairs, and service guardrails.

5. Materials and operating conditions

   • standard warehouse conditions or increased humidity/washing;
   • material preferences (carbon steel, stainless steel);
   • coating requirements (powder coating, color zoning, etc.).

6. Integration with equipment and automation

   • list of existing and planned equipment (conveyors, sorters, lifts);
   • requirements for placement of sensors, control cabinets, cable ducts;
   • specifics of IT and WMS systems affecting layout.

7. Installation and work organization

   • warehouse operating mode during installation;
   • permissible time windows and constraints;
   • need for phased line commissioning.

By preparing such a TS, you will speed up the calculation, reduce the number of clarification questions, and receive a more accurate proposal on timelines and cost.

The next step is to discuss your project and get a TS-based calculation.
Submit a request on the BRIX.UZ website or contact a manager, attaching:

• floor plan with dimensions;
• description of existing infrastructure (racks, conveyors, equipment);
• list of required metal structures (frames, guides, fencing, etc.);
• material and coating requirements;
• desired production and installation dates.

Submit a request for calculation — and get a technically sound solution for metal structures for your FMCG distribution center in Tashkent.