The VRC Buyer’s Guide Choosing a Vertical Reciprocating Conveyor

Vertical reciprocating conveyors (VRCs) are a type of material handling infrastructure designed to move loads between levels. They serve the same function as freight elevators, with one key difference: People can ride freight elevators, whereas VRCs are intended only for materials.

This distinction makes VRCs more cost-effective than freight elevators, both initially and throughout the operational lifespan. Freight elevators require frequent, costly inspections, for example. Standards for VRCs are more relaxed, so they’re less expensive to operate.  

Also known as material lifts, VRC can be used to move virtually any type of materials or equipment: pallet loads, carts, automated guided vehicles, and more. They’re a safe and efficient option — and in many cases, they can dramatically improve throughput.

To get the best possible results from material handling equipment (MHE), it’s important to choose the right tool for the job. Often, that means customizing the equipment for the task at hand: A custom vertical reciprocating conveyor can be a tremendous asset for a warehouse, distribution center, factory, or any other facility.

In this article, we’ll discuss popular VRC system designs and provide tips for purchasing (and customizing) your equipment. For additional guidance, call 1.800.BHS.9500 to speak with a member of our sales team.

Explore custom Vertical Reciprocating Conveyors from BHS, Inc.

Vertical Reciprocating Conveyors: Types and Applications

VRCs are available with hydraulic and mechanical lifting mechanisms. Each has advantages for specific applications:

• Hydraulic lifts are generally less expensive, but have a lower load capacity.
• Mechanical lifts have a higher capacity and may be appropriate for multi-story operations.
• Mechanical lifts may be significantly faster than hydraulic VRCs, and can typically handle more frequent cycles.

It’s important to remember that VRCs are not elevators: They’re covered by ASME B20.1, “Safety Standards for Conveyors and Related Equipment”, and workers must not use them as transport.

Depending on state or local building codes, material lifts may require inspection to verify compliance with ASME B20.1 — and as an employer, it is your responsibility to provide appropriate signage and training for workers.

Read more: Vertical Reciprocating Conveyors (VRCs) Vs. Freight Elevators

Applications for Vertical Material Lifts

As a solution for material transport, VRCs have dozens of potential applications:

• Distribution centers and warehouses can integrate VRCs into automated conveyor systems, sortation systems, and mezzanine or pick module applications.
• General manufacturing or assembly plants can move pallets, carts, totes, bins, and other loads into picking and kitting operations.
• Chemical and pharmaceutical manufacturers can utilize VRCs for multilevel applications.
• Printing operations can utilize VRCs to move paper rolls, die boards, plates, and printed materials in process between levels.
• Airports can utilize VRCs for luggage and baggage handling applications.

VRCs are widely utilized in a variety of other facilities. In industrial operations, they’re especially popular for moving pallets between levels: A material lift can accomplish this task much more safely and ergonomically than a standard lift truck.

VRC Designs: Choosing a Material Lift for the Task

To find the right VRC for your operation, you’ll need to consider the size of the loads, the footprint of the system, and the location of access points for loading and unloading.

The proposed location of the VRC is an especially important factor. Conveyors may be installed in existing elevator shafts or through-floor in an existing facility; if you’re planning a VRC during greenfield construction, you’ll have more options. However, if the equipment isn’t designed for the load, you may miss opportunities for optimization.

VRCs follow four basic design configurations, which have practical benefits for different types of operations:

1. Straddle Design Vertical Reciprocating Conveyors

Straddle VRCs center the lift carriage between two vertical guide beams. This design supports large platforms and high lifting capacities, but it typically restricts access to two angles of approach.

That means you can load and unload straddle VRCs from the same side or from opposite sides. For example, you might load a pallet onto a straddle VRC from the front at ground level, then unload it from the back on a mezzanine. For four-way access, choose cantilever or four-post designs.  

2. Cantilever Design Vertical Reciprocating Conveyors

Cantilever VRCs support carriages along a single mast, opening three sides up for loading and unloading. The footprint of a cantilever system is often smaller than other options, and guide beams don’t require as much vertical space.

Because the carriage is only supported on one side, however, cantilever systems may require extra bracing to offset load force. This design may limit platform sizes and weight capacities as well.

3. Four-Post Design Vertical Reciprocating Conveyors

A four-post VRC has its platform mounted within four guide beams. This enables the material lift to use extremely large platforms and handle high capacities.

Additionally, a four-post lift allows access from all four sides for loading and unloading. Bracing is recommended to handle the lateral loads (based on the specific application).

Four-post VRCs have a much larger footprint than other options, but they’re an excellent option for large or heavy loads.

4. Double-Mast Design Vertical Reciprocating Conveyors

Double-mast VRCs are similar in design to four-post material lifts. Both designs require four guide beams, but in a double-mast system, the carriage or carrier is cantilevered between the two sets of masts.

While the capacity and platform sizes are smaller compared with a four-post design, the overhead clearance of the load height isn’t limited to the structural cross members.

The primary disadvantage is that loading is limited to the two ends of the material lift. If an application requires a more flexible traffic pattern, cantilever or four-post VRCs may be preferable.

Gathering the Details: A Checklist for VRC Buyers

If your facility has any process that requires the transport of bulk materials between levels, a VRC may help you handle more work while protecting worker ergonomics.

Through customization, VRCs can be outfitted to handle large or fragile loads. VRC systems can be synchronized within an operation or designed with spark-proof or food-grade materials — and customizing material handling equipment allows operations to maintain small footprints while maximizing productivity.

When customizing your VRC, you’ll need to accurately analyze your operation’s needs. To get started, collect the answers to the following questions:

• How often will the lift be used?
• What is the maximum weight and size of the load?
• Will the platform be loaded by fork truck, conveyor, pallet jack, or via another method?
• Where will the unit be installed?
• Will controls be required at each level, or on the ground level only?
• Do the controls need to integrate into any equipment or sensors?
• Do you have any special requirements (such as spark-proof materials)?

An experienced MHE partner can help you design an ideal system for your facility and optimize your workflow.

BHS customizes each vertical reciprocating lift to meet the needs of the application. Our engineers are prepared to help you evaluate options. To learn more, call 1.800.BHS.9500 to speak with a member of our sales team or request a quote online.